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

I bought the plastic headliner as I didn't have the time to much around with trying to make a cardboard one. It can be done.. Look online as the plastic ones and it'll help you with where to place relief cuts.

I'm planning to cover mine with thin insulation foam (1/8 or 3/16") and then black vinyl or suede.

Riddler