Since I started this thread on the headliner, I thought I should give an update on our own headliner installation, given that I was overly optimistic on how close we were to install (by only about 7 months!). Hopefully this writing will help some other builders with information to make a decision (pictures at bottom).
With all the solutions discussed, we opted to attach the headliner with heavy duty Velcro (Lowes 15’x2″ black self adhesive 10lb hold, ~$28/roll). After inspecting the headliner and getting a feel for how it behaves, we were not ready to commit to a permanent adhesive solution (my complete thoughts on the headliner material I’ll post in a different thread). In addition to possible electrical expansion, we chose the Velcro option for these reasons:
1) the headliner seems to scuff and scratch VERY easily (it also arrived with gouges out of the box). Given that camp life can be dusty and dirty, often including unusual pointed objects, I’m not sure how anyone can hope to keep the headliner clean without damaging it. Any installation requires extreme care to avoid anything with a sharp edge – especially hidden dried epoxy boogers!
2) the CLC Hymnal purports the MiniCell is used in $100,000 sports cars. I’m sure this is true – but I’m confident it is also covered by some sort of upholstery to prevent damage. To avoid the complications described above, we will eventually find some material to stretch over each panel. Black speaker utility fabric (Joanne’s) is a leading candidate but there are other options. Thus, we need to be able to remove each panel in order to attach the fabric. We also figure we may eventually replace the headliner if it gets too damaged.
For our installation, we cut the tape into 1″x2″ rectangles oriented about 3″ from each other. Based on our progress, we estimate it will take about three rolls to achieve adequate coverage on all panels, although I’m sure you could stretch two rolls. We’re about 1/3 done as of this writing and very pleased with the results. The Velcro tape glue is more than adequate to hold the lightweight panels, and it does stick very well to the interior shell (we had epoxied and sanded the interior). Most importantly, we can remove the panels easily exactly as intended (see pictures).
During installation, we have noticed an added benefit to the Velcro… it is more forgiving than contact cement (provided you adhere it to the correct side and dry fit your panels beforehand). We found we can “slide” adjust panels using the hook/loop connections to push panels together, resulting in more attractive seams between panels (if we don’t get it the first time).
As for the concern of condensation: the Velcro does add about a 1/8″ gap between the headliner and the shell; however, we think this is no reason to discount this solution. It may actually aid in the insulating effect without condensation, as condensation is formed when warm moisture laden air (from the occupants) contacts a cooler surface (the shell). If the headliner prevents this air contact, then no condensation forms on the shell. To my understanding, the effect any insulation provides is achieved by creating an air barrier, like vacuum sealed doubled-pane windows. The air pocket created by Velcro then acts as a temperature barrier. (I’m not an engineer or steeped in physics, so please double check my work).
