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but only a few millimetres and not the roof .. !!!
Right?! lol i guess it's something you have to expect with the aftermarket nature of things. It's far worse when it comes to replacement sheet metal i hear, often needing much modifying. I remember Nige on his build had steel that was way out of proportion on the arches.
Think i've sussed the headliner now, it doesnt go all the way up to roof, its about 2-3 inches away, so when i was installing the sunroof trim, it was lifting it too high up and causing a pinch effect, hence the waves appearing. What i'm in the process of doing now is creating a 90 degree bend in the sunroof cut out area, as otherwise there is a 3 inch gap between the roof and the headliner which will look odd even with vinyl covering it. looking at the original headliner, it has an S bend around the sunroof area to create a flush finish. easy to do with carboard, but not so much with plastic, so i've been (don't own a heat gun) using a blowtorch on low setting to heat the plastic just enough to create a 2 inch flange. It's made the whole thing a lot stronger and it doesnt wobble which is kind of a bonus. didn't get a chance to trial refit it as its way too late, so will try tomorrow eve will see if it works.
Cheers for now!
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