My first car was good at getting me from point A to point B with decent gas mileage. What it wasn't good at was keeping cool in the summer and warm in the winter without a LOT of extra help. What it did good for gas mileage was often undone by how hard it had to work to regulate temperature because of bad insulation.

If I knew then what I know now, I would've saved myself the money and hassle by upgrading the car roof insulation. In the end, I could've saved the money by improving my car's fuel efficiency, and drive with a level of comfort rivaled only by a suite at the Ritz-Carlton!

Read on to learn about roof insulation options that can keep the interior temperature just the way you like it.

A Second Skin customer's sprinter van insulation project where he lined the roof with Mega Zorbe, our best automotive insulator.

The Headliner needs insulation

The headliner is the series of layers covering the ceiling of your vehicle’s interior. A knit fabric layer covers a foam-like layer of polyurethane that adheres to the fiberglass roof. This entire unit is the headliner, responsible for insulating over-head. We use R-value to determine a material’s capacity to resist heat flow.

However, outside of luxury vehicles, this standard layer of polyurethane in most cars is usually minimal, leaving significant room for improvement. And per the Department of Energy, your air conditioning is the #1 cause of reduced fuel economy in hot weather. Blasting the AC can reduce fuel economy by more than 25%.

Benefits to upgrading roof insulation

Upgrading your roof insulation will create a noticeably more comfortable cabin by helping maintain temperatures inside the vehicle, and with less cool air escaping in the summer, it'll take less energy to keep the vehicle cool. Better gas mileage and more comfort? Yes please!

The additional insulation will also absorb echoes for improved audio clarity and reduced noise from rain and other weather. Some customers even find themselves turning the volume down since airborne noise is less of an issue! And if you have a sub in the trunk, we don't need to tell you twice about the benefits of reducing roof flex.

Mega Zorbe™ Car Roof Insulation

Our two recommended car roof insulation materials of choice, Heat Wave Pro™ and Mega Zorbe™, are lightweight, high R-value materials that are thin enough to fit behind your car’s upholstery and panels. When you get into the bones of the vehicle, you want to make the most of your time and effort. Deciding which one best suits your needs comes down to space and overall intent.

Heat Wave Pro™ is a great thermal insulator made of recycled jute sandwiched between two layers of foil, to be applied directly to the headliner. Because the foil reflects radiant heat, with even a tiny air gap between the headliner and the roof, combined with an R-value of 3.91 per inch, Heat Wave Pro™ provides excellent thermal insulation and radiant heat resistance. It's only 3/8" thick and can be compressed for tighter headliners.

Mega Zorbe™ hydrophobic melamine foam is an industry-leading combination of thermal and sound insulation. These aerospace approved, melamine foam sheets are ideal when you have at least 1/2" of space between your car roof and the headliner. You don’t want to squish Mega Zorbe™ due to the open-cell structure. If you’re limited to less than half an inch, we recommend sticking with the Heat Wave Pro™.

INSTALLATION TIPS

For Heat Wave Pro™ and Mega Zorbe™, use a good pair of scissors to cut to size.

Cut it down to the size of the install location first, making sure to leave room for wiring and other electrical components.

If your project calls any amount of sound control (and truthfully it should), you'll want to get it done while everything is exposed. Deadening roof noise and putting a stop to roof flex are a part of any good car roof soundproofing project.

The most effective sound deadening mats are made with both a base of butyl rubber and a sturdy constraint layer—Damplifier Pro™ Sound Deadening Mats are just that. With 100% coverage of Damplifier Pro™ you are also adding an extra layer of thermal protection, even if its "main" purpose isn't thermal insulation. We love bonuses benefits around here!

Alternatively, Spectrum™ Spray-On Sound Deadener, a water-based viscoelastic polymer for liquids and sprays, can be applied directly to the metal to resist the vibrational energy and add a layer of thermal protection.

INSTALLATION TIPS

Cut Damplifier Pro™ with a sharp razor blade to get clean, precise lines.

Damplifier Pro™ Car Roof Sound Deadening

The first step in removing the headliner is to remove all attachments, like grab handles, seatbelt heads and brake light covers. Next, you’ll remove the trim pad panels that run along the sides of the headliner. This will release the headliner from the roof of your car, at which point you can simply pull it out. Make sure to check out that pro tip!

PROFESSIONAL TIP

Take notes and/or photos of your car’s headliner as you remove it. The reference will help you reinstall the headliner correctly when you're done putting in your new insulation.

Sound deadening material is part one of our Second Skin System. While the primary function is to deaden vibrations, with the recommended 100% coverage, our sound deadening material is going to act as a second thermal layer for when it's really hot or cold.

Damplifier Pro™ should be applied first as your vibration reduction layer. Damplifier Pro™ comes in sheets that you can cut to size with a sharp utility knife for easy application. Installation is fairly simple – just cut to size, peel to reveal the built-in adhesive, and stick. Most people get a wooden hand roller to roll it onto the metal sheet and ensure a firm bond.

If you choose to apply Spectrum™ liquid deadener, you can spray it on with a spray gun or simply paint it on with a brush. Spectrum should be applied in 1mm layers to ensure proper adhesion. For most situations, we recommend doing at least 2mm total but no more than 5mm. This is an important step to solving noisy vehicles like Ford Bronco noise.

The car roof thermal insulation – Heat Wave Pro™ or Mega Zorbe™ – will go on next as the heat barrier layer. Heat Wave Pro™ should be attached to the headliner using spray adhesive or double-sided tape. Cover 100% of the roof, as this application will fight gravity, heat, and movement on a daily basis. Tape the seams and edges to protect them from daily wear and tear.

If you decide to use Mega Zorbe™, make sure you have at least a 1/2" of clearance, as it’s an open-cell foam and needs to be fluffed out in order to be effective. You can easily peel & stick with the PSA backing, or use a spray adhesive to adhere it to the Damplifier Pro™.

After the vibration and heat barrier layers have been applied, reapply the factory foam material IF you have extra clearance. With insulation, more is almost always better.

PROFESSIONAL TIP

Your average car roof is 20-25 sqft. But like Mom always said… Measure twice, cut once! Thanks Mom.

Okay, okay! We have two options that will take you from dud to stud! Whichever you choose, complete coverage is a must, so always measure to find out exactly square footage you need.

If you have limited clearance or are on a tighter budget Heat Wave Pro™ jute insulation is highly effective with an R-value of 3.91 per inch. Install it on the headliner to gain the added benefit of the reflected radiant heat in the summer.

If you're looking to improve the acoustics inside as well, Mega Zorbe™ hydrophobic melamine foam does just that with an R-value of 4.16 per inch! You'll want to be certain you have at least 1/2" of clearance as this open cell foam technology only works when it's not compressed (that's why we don't suggest it for insulating a car floor.).

PROFESSIONAL TIPS

Attach your insulation with with spray adhesive or strong double-sided tape (if you don't get the adhsive backing). Be sure to also tape the seams.

Don't throw out the factory car heat insulation (unless it's gross or completely worn out)! Save it in case you still have room above the headliner when you complete your install. Extra layers will increase the total r-value and further reduce heat transfer!

If you’re looking for the quickest and easiest way to get maximum results, consider a Second Skin Audio Car Roof Kit. It's easy to toggle between the various options discussed in this article, and each kit combines exactly what you need to get the job done (with a 10% discount included!). Aside from the soundproofing and thermal insulation materials, each kit also includes any needed adhesives and tools to make the job easier.

• Damplifier Pro will stop your car's roof vibrations whether you're trying to max out your SPL or just drive in peace and quiet.
• For your insulating layer, choose between Mega Zorbe and Heat Wave Pro. Both materials will absorb sound and resist heat transfer.
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