Thanks again for the replies and comments (both here and via email, etc). Since mentioning this, I've made a replacement headliner (both pieces) and as soon as I install insulation, do the final adjustments and decide on a color I'll paint it and install it. One additional idea came to me and I've tried it on a scrap piece of the thick paper with good results. Wood glue. Actually what I had on hand was Titebond III Ultimate Wood Glue I had bought to rebuild a foundation access door that's exposed to rain, wind, snow in New Mexico. It isn't as cheap as school glue (it is $8 or $9 for a 16 oz bottle), however it is waterproof and rated interior/exterior. Interestingly it doesn't claim to be sandable but in my experience it seems to be. The headliner I made was just glued up with common school glue and will be sealed with Minwax plus paint on the front, edges and back. You can see it partially installed below. Aside from needing the edges trimmed a bit, it seems good. More to follow as it happens. As time allows I will make replacement door panel pieces. FWIW, 4 layers of the .5 mm thick paper laminated into a nice thickness.
~ Jon 1952 1/2 ton with 1959 235 | T5 with 3.07 rear end
