Apparently the early KIA Picanto models are known for having an bad roof lining which tends to loosen over the years. This was also the case with my Picanto from 2005. First I considered to fix the lining by just making a clean cut in the middle adding some new glue and press it all up again. But sins the fabric has shrunken over the years it would be impossible to get a outcome that looked good. So after some searching online I found blog-post in german with detailed description.
It didn't look to complicated and could be done in one day, so i set out to take up the challenge and try it out myself. I have tried to document the process best possible with a lot of pictures so it's easy to follow along.
Start with dismounting all the handlebars, sunscreens and the roof light. In the back there are 3 plastic knobs, which can be puled out by pulling down entire roof lining. Put all pars, knobs and screws in a box so you don't loose any.
Next up are the plastic covers over the pillar/columns. It can be tricky to get your fingers under the plastic cover. Make sure to pull the cover apart with one firm quick pull. Pulling slowly will most likely bend the plastic cover.
Now the entire roof lining is free and can gently be pulled trough the back of the car.
Start at one corner and work your way gentry trough the entire roof. My fabric was still quite stuck to the roof cardboard form in the front where the sunscreens are located. With a sharp knife i loosened the fabric gently and could pull it off.
Make sure not to rip off the fabric to hard, so that the cardboard beneath don't get damaged.
After the entire fabric comes of use sandpaper to remove the left over fabric parts and the old glue. Quickly I got tired of sanding down the cardboard by hand so i used a orbital sander. When using the orbital sander make sure to use with slow speed to not damage the cardboard.
Remember to sand down the entire cardboard so that the surfaces gets a little ruff, this will later on help to make the glue and fabric stick better together.
When done sanding the cardboard make sure to remove all the dust and leftover glue and fabric. You can vacuum it ore like I did, use a compressor to blow it all off.
It is best to take the cardboard roof inside to prevent dust and sand to be blown on it when outside. Also does the glue not dry to fast when the weather is warm and the sun is shining.
But make sure to have windows and doors open when working with the cleaning benzine and glue. They can have toxic fumes and give you headache and dizziness when used in a closed and bad ventilated room.
The last thing left is to wipe of the entire cardboard with cleaning benzine before putting the new fabric on. This will remove the last leftover glue, dust and finger grease. This will help to make the glue stick better to the surfaces.
One not one the fabric first. I went with black, since I could not get the matching light grey color for my KIA Picanto. The new fabric is also thicker than the original one, but this was no problem for gluing it on the cardboard roof.
Lay out the fabric in the middle of the cardboard roof and make sure to have a good amount of overlap to the sides and the front and back.
Now lay over the fabric in the middle and start brushing the glue in a thin layer on both the cardboard and the fabric. Now flip over the fabric and press it to the cardboard. Whit a little hand broom sweep from the middle of the cardboard to the left and right sides. Make sure that there are no "bubbles"! When the glue starts drying, it is not possible to lift of the fabric again.
Work your way trough to the end of the cardboard. I had to work quickly, since the glue was drying quite fast in the warm weather.
When done with the first half, flip over the fabric and repeat on the other side. When coming to the models for the hand grip and sunscreens make sure to press the fabric around all the curves and corners. Make sure to glue and bend over the fabric at the edges too.
After done with gluing the fabric on let it sit for 30 min. to make sure everything is dry.
Now take a sharp knife and scissors and cut of the leftover fabric. Make sure to still have a couple of centimeters overlapping the edges all the way around. Later on when putting the roof back in the car fold the overlapping fabric around the cardboard edges to have a nice and clean finish.
With the sharp knife cut out all the holes for the handlebar and sunscreen mounts.
Put the roof back in KIA trough the trunk, make sure not do damage the new lining, there is not much space to work with.
Now work your way from the front to the back. Aline the cardboard roof with the front window and push it gently into place.
Pressed the roof up under the rubber lists/moldings halfway trough the car. Than fasten the plastic panels in the front pillars. Now continue to the center pillars and work your way trough the car all the way to the back.
The hardest thing was to get the cardboard roof under the big plastic panels in the truck. But with some gentle bending, pulling and pushing you will get there.
Now the last thing left is to mount back on all the handlebars, sunscreens roof light and the 3 little knobs in the back of.
Finished, now grab a bear and enjoy your handy work, you have earned it ;-)