The strips were something like 120 inches long, and the guy I was working with was a perfectionist, so the strips had to be nice and straight. I had to cut the strips and the foam to make the t'n'r rows. If I recall, the owner wanted 8 to 12 rows of tuck'n'roll in the center of the headliner, and the rest flat vinyl-all in pearl white. I remember in the early 2000s I was working in a shop and I got to help put a tuck'n'roll headliner in a chopped Merc. That is some great work I was an upholstery apprentice a few different times in my life, and unfortunately I wasn't able to stay with it for very long each time. Hope this helps, but sometimes the best way is to get a local trimmer to show you first hand. The fancier you want it, the more time it will require. Larger flutes can be done with a strip of wood and strips of cloth to shroud the cotton. I made my fluting spoons out of stainless pipe and polished the edges to keep it slippery. Fluting usually require a larger pleat size and the stuffing is cotton. The process of stuffing the pleats after the fact is usually referred to as fluting. You can channel the higher density foam for a nicer affect. Some times you will have to keep the foam trimmed back from the piping line to keep the thickness manageable for sewing on the piping and next panel. You can play with the roundness of the roll by changing the width of the pleat and by changing the thickness of the foam. Tuck and roll can be done by slicing your material into the appropriately sized strips and can give you better control while sewing. Just because it's flat doesn't mean its not tuck and roll. Tuck and roll refers to the process of tucking the material back on itself and sewing it, then rolling the material over to the next sew line. REAL Tuck n Roll with "PRONOUNCED, STUFFED ROLLS" This is an example of the EASY poor tuck and roll that is commonly seen, notice how "flattened it looks.hardly any foam. I see to many interior that look "FLAT" and not "stuffed" and "rounded" It seems like a "lost art" in many aspects because of the cost and time consumption of doing it correctly. Being a purist of sorts, I would like to create the real deal. I know they used to use metal half tubes to stuff with cotton and the slide this in and then hold the cotton and slide it out. Technically "real" tuck and roll involves hand stuffed individual tubed pleats that are then sewn together. I once saw video of a guy doing the real tuck n roll: Does anyone have pics or this video? I have a Consew walking foot, have stitched a few interiors. I would like to do my own tuck n roll in a 56 Chevy I recently acquired. OR even worse, it is a sewn pleat with the sticking exposed. I've seen a lot of cars where people claim they have tuck n troll but it is really nothing more than a sewn over foam - that has then been back sewn to hide the first stitch. I know this has been discussed before but I can't find the videos/tutorials.
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