Thanks for all helpful suggestions and information. Much appreciated.
I went back and checked the bill from Rock Auto and it was actually $240 shipped. Sorry for exaggerating the cost. I had looked at a few places before buying and the price and shipping varied greatly, so that must have tainted my recollection.
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When I got home from work yesterday I dove right in and did trim the sides slightly based on where I had marked the plastic after peeling back the liner. I didn’t remove much, I’d say about a quarter inch from each side. I ran out of time and wasn’t able to get everything reassembled, but I did realize something… when I had removed the sun visors to pull down the front edge and mark the location for the rear view mirror, I didn’t reattach the visors before looking at the side trim. As it has been pointed out, this caused the liner to not be pulled tight against the roof. That accounted for some of the discrepancy.
I also noticed that temperature makes a difference with how well the plastic conforms. I had inadvertently turned off the heater in the garage prior to starting the install, so the first day I tired getting it to fit it was cold out there. Having the garage warmed back up I found it takes much less effort to push the headliner into place, so I think that was part of my problem too.
I should have some time this evening to get back at it and I’ll update again.
