Totally non-standard headliner type, apparently.... help?

[neroden]

After getting the news that every single Model S will come with a headliner which I'm allergic to (Alcantara == polyester), I inquired about the nature of the headliner, because headliner replacement is usually relatively cheap and simple as custom work goes.

This is what I got back:

"The headliner is approximately 3.0 thick sheet molded compound with fabric laminate covering that is bonded to the substrate in the tool. It can be re-covered (over the top), but the existing Alcantara cannot be removed without damaging the panel. It would difficult to completely pull off the fabric and replace it. I also inquired about a "blank" headliner delivered with no Alcantara. This will not be possible because the material acts as a mold release in the forming process. "

This appears to be completely nonstandard, unless I'm misreading the message.

Unless I can get specific information on how to re-cover this sort of headliner, or over-cover it with non-permeable material, I will probably have to cancel my reservation, because custom shops won't know how to do anything with this headliner.

Yuck. Can anyone help.

EDIT: from what I can tell, standard modern headliners are foam-backed material glued to a plastic (or whatever) board, and are normally scraped off very carefully at the custom shop. It's not clear what can be done with Tesla's headliner design, however, as it sounds like they've done something different.

This is make-or-break for whether I can get the car or not; if it's impossible to redo the interior so I'm not allergic to it, I just have to cancel my reservation and wait for a company to come out with an electric car where it is possible to redo the interior. Anyone with deeper understanding of what Tesla is saying, who thinks there's a straightforward way to fix the headliner, let me know.

[dsm363]

If the headliner is covered and it's not something you touch directly, does it still cause problems? I imagine it must be next to impossible to find a car that doesn't have some polyester so that must be tough.

[Grendal]

It sounds like they can add a fabric layer of your choice over the top. Are you allergic to alcantara specifically? Unless it creates something that falls off (like alcantara dust) I don't see how you can be directly allergic to the fabric if you can't touch it. I'm not trying to disagree with you, I'm just trying to understand the parameters of your allergy and needs. As dsm363 pointed out, plastic is everywhere and all around you.

If it's that the fuzziness of the fabric attracts dust, maybe you can coat the fabric in some way...

[Bearman]

Alcantara is 68% polyester and 32% polyurethane any fibers released from the cloth could affect him and I think all cloths releases tiny amounts of its fibers over time, if the alcantara cant be scraped off the headliner best would be to cover the alcantara with something else that keeps any fibers from getting in to the air. The problem is gluing something to the alcantara and have it look smooth but it should be doable. Another source for allergies are compounds released from the substance when heated, in older cars you can sometimes smell them when the car has been sitting in the sun. The panoramic roof would cut out a large part of the alcantara and without the large flat alcantara surface it might be easier to cover the rest of the fabric and have it look good.

[spatterso911]

That's an excellent thought, Bearman. Minimally, neroden should consider the pano roof to minimize the alcantara.

[richkae]

That's an excellent thought, Bearman. Minimally, neroden should consider the pano roof to minimize the alcantara.

With the pano roof, maybe the headliner is small enough that it is easier to be completely tear it out and have a custom new one made by a custom shop?

[Tommy]

In reading the various posts on the forums, I was left with the impression that it was only the Signatures that were getting the alcantara, if that were the case a production model might be the solution for you. I guess I would double verify what the headliner is made of and talk to several custom upholsters about a solution. Sounds like you're on top of this already, hate to see you not get your car thou.

[Lloyd]

That does not sound different from any other headliner. Removing the old is difficult and time consuming, but once done, recovering it should not be a big deal.

[gg_got_a_tesla]

In reading the various posts on the forums, I was left with the impression that it was only the Signatures that were getting the alcantara, if that were the case a production model might be the solution for you. I guess I would double verify what the headliner is made of and talk to several custom upholsters about a solution. Sounds like you're on top of this already, hate to see you not get your car thou.

I think neroden has a catch-22 situation here. I think he had mentioned earlier that General Prod cars have a lot of polyester in the door linings and such while all that's leather in Sigs. So, dropping down to P from S is not an option either for him, I guess.

[vfx]

Why not remove the liner and seal the alcantara. Either by a spray plastic/paint/rubber/latex/whatever or skin it with a shrink wrap cling material or a vacuum bag. Then cover the now safe form with baby seal skin.