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I had it recovered in Alcantara and deleted the sun visors....looks good, the only problem is that the headliner is just a bunch of pieces of cardboard, layered and bonded together....the cardboard layers have started to come apart in areas, especially up front by the A-pilars and it doesnt look very clean. I tried rebonding the areas with super glue....turns out that produces a chemical reaction with whatever the factory uses that produces an extreme amount of heat (burnt my hand) and some pretty toxic fumes.
If you're intersted in replacing your headliner with the '02 version which doesn't have the bulge at the rear, the model code is Y 37 (2dr coupe) GM part number is 10253386.
I believe that was the part number I used a couple of year ago when I did mine. You may have a dealer do a nationwide seach to see if there may be one left in stock somewhere. Its worth the effort to get the extra room.
One note, if you thought the '03 model was flimsy, the '01-'02 is flimsier, be careful putting it in, especially around the sun visor area.
Maybe not SOL yet......I have a pristine headliner from my '03Z for sale. Problem is, I havent figgered out a good way to ship it anywhere due to its large size. Plus I cant find a suitable box. Any chance local dealerships and/or bodyshops have a box I could use for shipping? Im in N. Ala, so shipping probably wont be toooo bad (if I can find a box)??
Also, the 03 -04 headliners have extra padding/collision whatever in them, so using a 03-04 headliner will result in about an inch less headroom compared to previous years. 02 headliner might be included in that too, not sure when the extra head protection/crash requirement was implemented. If you're short, no problemo
If you're interested, I have a thread in the C5 parts for sale section for my headliner.
good luck,
john
Last edited by Gear Jammer; Feb 12, 2011 at 09:27 PM.
Reason: Info added
Maybe you can use your old one as a template to create a fiberglass mold for a new one? It's a bit of work, but the fiberglass one won't ever disintegrate on you like the stocker.