Sanderson,
I'm working with my headliner right now too and I looked at some alternatives before going with the "off the shelf" headliner. Have you thought about using some alternative material and cutting your own based on your 3 bad headliners?
I looked at some flexible 4x8 plastic paneling from the home center (used in bathrooms and high-humidity environments). It was flexible enough to bend to fit and inexpensive. I purchased headliner material (foam-backed fabric) with that intention.
However, I eventually ordered a cardboard headliner from American Classic and mine fit great. I made that choice because I didn't want to try to create a pattern from scratch. Since you have the pattern (the bad headliners) it might work for you.
I covered my cardboard headliner with headliner upholstery material since I'd already purchased it. I finished the edges with motorcycle trim molding from JC Whitney and I'm really happy with the results. I've got the back piece in, but I'm waiting for a "helper" (either my husband who is out of town hunting, or my sister) to give me the extra hand I need to install the front piece.
I'll take a photo and post a link here
54 Project Pics for you.
Sorry about your bad luck - I had a great experience with American Classic.
