I'm almost positive you seen my thread where I made my headliner? But anyways with a pretty good idea of how it's done and what to use I can't imagine it taking more time than it would to order one and wait for it and get it open it and test fit it and recut it again and again. I would be thinking at this point it's going to have to be taken out and it's going to have to be putting back in and it's going to have to be fitted a couple times and test cutted. And as you say you're going to have to want to glue the headliner on also...
I know this doesn't help the original poster or any but if you're taking your headliner out anyways and to give it a $15 shot to slap it down on a piece of 1 ply plywood. Cut out a replica of your old one. Get a $15 can of that glue spray and $15 worth the headliner material at Jo-Ann Fabric and Valla...
As far as the time scale I would think most anyone within a half hour of a city limit could be to the lumberyard in Jo-Ann Fabric and back home within 2 hours and since the headliner is out you could slap it down on that plywood trace it and cut it out within an hour and I think you're already at about where you're piece of plastic comes in for $300? Just for conversation sake? Also I do agree with everything you're saying about the headliner it's not easy either way or...
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