I made mine by laminating school glue and heavy floor protecting paper I got at Home Depot. The roll had more than enough to make 2 or 3 headliners, door side pieces and a couple of new glove boxes (a different design because of the A/C unit). It turned out to be pretty easy work and is tougher than the cardboard sold today. As I recall I used three laminated sheets...could have been four but I think it was three. I used the headliner I had made about 40 years ago as an outline and had no trouble at all. After it dried a couple of days I removed it and painted it a flat tan color.

I also used some self-adhesive neoprene sponge (about 1/8 inch thick) after I painted the top inside part. After that I also installed some of the higher R value HVAC duct insulation (foil all around and about 4 inches of fiberglass in the middle). You can work that stuff pretty easily and if you use some double sided tape to hold it in place it works nicely. I flattened it where the bow goes so I would have insulation all over up there. One thing I learned from the work I did many years ago...don't overlook insulation up there. What it does is it keeps your headliner from shrinking where it goes down under the windlace rubber. The cardboard will shrink to some degree and I don't believe you can stop that however the insulation will push against it and minimize the process. Also all that insulation makes for a much less noisy truck. In a good rainstorm mine used to sound like somebody beating on a washtub with a crescent wrench. Much better now. Good luck!

~ Jon
1952 1/2 ton with 1959 235 | T5 with 3.07 rear end