can/has it been done?? home made headliner...

Maybe you can try taping together a template made out of cardboard? Just to give yourself some parameters for when you cut your final material...
Just a thought...
Also Make sure you quote me directly like you did so I get a notification or use the @j par to get me quoted in and I'll help anyway I can...

Yes, making a template of cardboard was the way we WERE going to go, BUT.........over the weekend I went to a guy's place, who I met at the Mopar Nats. He lives about five miles from me. While looking for some other stuff, I saw a headliner sitting in his rafters about thirty feet above us. He says " Yeah, that's an old black headliner out of a Dart" !! Forty bucks later, it's in the bed of my truck ! I think I can salvage it pretty easily ( couple corners frayed, dirty). Classic Industries sells the sail panels, so just have to figure out how to attach everything. Now just have to repair the one I have for '74 Duster, and we are good. I like the fiberglass idea from other gentleman. Have done a good bit of fiberglassing redoing an old Bass boat.