DIY Network

Carbon-Fiber Interior: Remove Interior Trim From "Tricked Out" episode DTRK-201

	The project car: a 1997 Honda Civic hatchback.
	Under the hood: the 1.6-liter single overhead cam engine produces 106 horsepower. The owner has upped the ante with a short-ram intake system, a cam and pulley kit and red 9mm plug wires.
	Media Watch the video on the featured project car.

NOTE: Images on this page may be enlarged for enhanced viewing simply by clicking on them.

In this episode of Tricked Out, the interior of a 1997 Honda Civic hatchback is dressed up with the coolest in carbon-fiber accessories. The look is hot and this car's interior will show a dramatic change after the project is complete. Host Andrew Totolos adds custom overlays to the dash, console, vents, doors and even the headliner. Other carbon-fiber accessories, like a shift knob and e-brake handle, are added to the interior as well.

In this first segment, host Andrew Totolos begins the process of removing the factory-installed headliner and trim panels in the project car to ready it for a new carbon fiber headliner. The interior gets a good clean up and then the in-dash overlays get added to the dash, console and door of the car.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Dash overlay kit
Headliner
Cargo cover
Shift knob
Emergency-brake handle
Panel-removal tool
Grease and wax remover
Fine-grain sandpaper (optional)
Spray paint made for fabric and vinyl (optional)
Fasteners
Adhesive promoter
Masking tape
Rubbing alcohol
Paper towels
Hacksaw or rotary tool
Cordless drill and screwdriver attachment

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 3 on a 5-point intermediate-level scale. There's a little cutting involved, but for the most part you'll just need standard automotive ratchets and a screwdriver in terms of tools.

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

Safety Alert: As a standard safety precaution, always disconnect the vehicle's negative battery cable before you begin work on any electrical or mechanical components.

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Project Car

This project is being performed on a 1997 Honda Civic hatchback, one of the most common platforms for modifications and performance enhancements. Civics are well-made, inexpensive to own and have numerous options available in terms of aftermarket parts. This particular vehicle belongs to Brandon Winston who has already added a few upgrades in the form of dual angel-eye headlamps, chrome-and-clear tails, gun-metal vinyl graphics and matching 17" polished-lip wheels. Under the hood, the 1.6-liter single overhead cam engine produces 106 horsepower with 103 foot-pounds of torque from the factory. But the owner has upped the ante with a short-ram intake system, a cam and pulley kit, red 9mm plug wires, a hyper ground-kit, a performance engine-control module, and full 2-1/2" down-pipe and exhaust.

The Carbon-Fiber Craze

Carbon fiber components are for more than just looks. This high-tech composite is stronger than steel, but weighs half as much -- which is why it's used in building race cars. It's more expensive than steel, however, which explains why it's not used more often on standard consumer vehicles. But as production costs are coming down, carbon fiber parts are finding their way into increasing numbers of enthusiast vehicles in the form of aftermarket parts. The most common carbon-fiber swap is the hood, which may save twenty pounds or so off the stock weight of a vehicle. The material has also caught on for numerous body parts and interior accents. For this project, we focus on the interior -- including the dash, console, vents, doors, headliner and a couple of added accents. We begin with replacing the existing the headliner.

Carbon-Fiber Headliner: Prep Work

Every car is different, but in most cases the headliner is under the plastic trim pieces that cover the roof pillars. The pillars pieces are under the side panels and the side panels are under the back seat, so it's all got to come out. One our project vehicle, the back seats had actually already been removed to make the car lighter. In most cases, you'll need to remove the back seat before you begin the real work.

Once you have the seats removed and you get to the plastic, there are a couple of things to keep in mind. Don't rush. Plastic trim pieces and fasteners get brittle with age, especially the kind up in the roof that get hot in the summer sun. You don't want to get in a hurry and break anything, so allow yourself plenty of time, and be patient. Second, you're going to end up with a lot of little pieces and parts that could easily get lost, so keep them all together in a container so you can find them when it's time to put everything back together. Separate labeled containers for each panel or work area will simplify things even further.

There are several types of fasteners you're likely to encounter. Sheet-metal screws are the strongest, and you'll usually find them hidden behind a cover or inside a compartment or door jamb. Expansion grommets come with screw type or pop out centers. Just back out the center pin, and pry out the grommet with a panel-removal tool. Push type grommets have a smooth finish and are used where they will be in plain sight. A panel-removal tool will pop them right out. Finally, panel clips are hidden fasteners that release when steady pressure is applied to the panel.

Figure A

Steps:

• Remove backseat from car.

• After seat is removed, pull out rear carpet (figure A) to expose any fasteners underneath.
  

• The weather strip should be released from the hatch opening (figure B) and tucked up out of the way.

• The rear center panel comes out (figure C). It's attached with two grommets and panel clips at the top.

  Figure B

  Figure C

  
  

• The rear lower side-panels are next. First the speaker covers are removed (figure D) and several fasteners in the lower side panels are released (figure E).

  Figure D

  Figure E

  
  

  	Figure F
  	Figure G

• When all the fasteners are removed pop the panel loose at the back, then pull the panel clips free at the door.

• Unplug the speaker connection behind the rear of the panel and then pull the panel out through the hatch.

• The upper-rear trim panel is mounted underneath the seatbelt. Slide the seatbelt from behind the guide, then remove the 17mm bolt that secures it to the B-pillar (figure F).

• Remove the three screws underneath the rear window and pull gently to release the panel clips starting at the back of the car.

• Pop off the trim and remove it through the passenger door (figure G).
  

  Back seat and interior trim removed from the Civic hatchback.

• The remainder of the panels are removed in the same way: unscrew, unbolt and pop out. The front trim-panel is held in place with panel clips. It should pop right out.

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

RESOURCES :

Special Resources for Tricked Out episode 201

Vibrant Performance
Website: www.vibrantperformance.com

Topshop Co.
Website: www.topshopheadliners.com

DragonAutomotive.com
Website: www.dragonautomotive.com

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