NEXT-GEN HEAD LININGS
The World’s Best Head Linings For Land Rover® Defenders.
Next-Gen Head Linings are a state of the art product developed by Defender 71.
Following much development work to create this amazing product, we are now able to offer these liners for sale. Currently on an 8 week lead time due to demand, we will be increasing our supply in the near future to stock off the shelf.
Why Are NEXT-GEN Head Linings So Good?
We produce these linings in a state of the art modern UK Manufacturing unit, using substrates and processes developed in the automotive industry over many years and are now the very latest techniques in this type of production.
At each critical point in the process the component parts are monitored with high end technology such as thermal imaging cameras to ensure the tight tollerances are adhered to.
We do not use any glues at all and the key production processes are fully automated, to create a product that is so precise you would not believe!
So How Do We Do It?
Well that would be telling! But working with a team of 3 UK companies, we have come up with the perfect Land Rover Defender Head lining.
In short, we use a light weight fibre reinforced thermoplastic and during the moulding process, we weld the outer fabric onto the substrate to create an almost unbreakable bond. Finally we ensure a precise fit by trimming the edges using CNC machinery and a high pressure water jetting system.
SIMPLE, BUT VERY EFFECTIVE!
You will not be disappointed.
Why Does The Genuine Land Rover® Head Liner Fail?
Having traded in the Defender head liner market for over 5 years, we are too familiar with the problems that are inherent to the product.
Developed some 30 years ago the process has stayed the same from the initial liners to the final 2015 Model range.
Defender owners have been plagued with sagging head liners and I guess those taller ones among us have even developed bald spots from it.
The sagging stems from the problematic production process and as long as it is made this way the problem will not be eradicated!
How Are The Genuine Land Rover® Head Linings Produced And Why Do They Not Last?
The liners start their life as 2 separate parts, the outer fabric face and the backing substrate shell.
The backing substrate comes into the factory as a large piece of felt, like underlay, made from all sorts of different types of fibres, these fibres are impregnated with a powdered resin, which under extreme heat 250 degrees Celsius and over 20 tons of pressure are melted between a male and female mould.
Once cooked the liner is placed on a cooling mould to ensure the shape is retained until it is rigid.
The moulding operation does not trim the excess felt from the liner and this is carried out manually.
The substrate is then sprayed with a glue manually by an operator and placed on another mould, where the outer fabric again under pressure and a lower temperature, about 50 degrees celcius, the fabric is glued to the substrate.
The roughly finished liner is then trimmed and the outer fabric edges wrapped, glued and stapled to the back of the substrate.
Where Things Go Wrong With The Genuine Land Rover® Head Linings:
The Moulding Process:
There is a fine line between over cooking undercooking the substrate, over cooking it gives you an awful fishy smell that will stay with the vehicle for months and months and undercooking it will make the liner flimsy and more susceptible to moisture, which in turn will cause the liner to either delaminate or sag and quite often both.
The Trimming Process:
Poor quality fitting can quite often occur from the old moulds being used and the cooling process being rushed, so the liner does not have time to form a rigid substrate. Also accountable to poor quality fitting would be the manual trimming operation.
The Gluing Process :
Is there enough glue on the substrate or is there not?
Has the glue cured long enough before it goes into the press or has it not?
Has it been in the press long enough or has it not?
Due to the fact the liners are produced in an environment that is not climate controlled, external temperatures and climatic conditions all have a large bearing on this process and can create a finished liner that could last a few years or a liner that lasts a year.
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