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

It's a great big piece of special paper/cardboard/ etc. laminated or painted to give it a texture and then die cut on a really big clicker press. It's also got to bend and curve to fit the contour of the roof and to meet up with the creased edges. Unless you're seriously into origami and have pro upholstery skills I'd ask a local car upholstery shop what they'd charge, if for nothing else than to get an idea of the work involved. I'd wager they'd charge as much or more as just buying one. Short of that I'd try to find a used one and cover it will some new material. Or sell some stuff from your spare parts bin(?) to just buy a new one. Another alternative might be to put a cloth one back in it, if the sill area was made to accept the clips that held the bows in place. Not sure if once they went to cardboard liners if they stopped punching those holes for those bow fasteners.