Replacing the Headliner
I had a similar headliner and hull liner problem with the vinyl-backed foam headliner in my 1991 Moorings 38. The glue and foam were mismatched by Beneteau in the factory, causing the foam, over time, to turn to dust and the headliner all fell down. The dust prevented gluing the old headliner back up. I took out all of the old headliner and replaced it with a similar vinyl backed foam liner, 1/2 in. thick. The hard part was getting all the foam/glue dust off the hull and out of the boat. The stuff gets everywhere. This required wiping the hull down with "Goof Off". And using a plastic scraper to get the resulting goop off the hull. Definitely unpleasant and sticky, and requiring a vapor mask and lots of ventilation. I used the old pieces as patterns, except where the cabin furniture had been bolted on top of the liner during construction. We sewed the edges where necessary for a finished look. Then I put the new vinyl up with Weldwood Gel Contact Cement, gluing it directly to the hull. This has held up well with no problems through this past summer season in Florida. I had to do the entire boat: aft cabin, aft head, forward head, main cabin and forward cabin. Used something like 25 yards of the vinyl. It is a time consuming job but well worth it when finished.
