Bill -
Let me suggest a different approach to the headliner issue.
I watched a counter top builder measure a counter top in a new home to fit to the various waves in the walls and into the not square corners and I used his method.
I used about four to six smaller than full headliner size pieces of cardboard or even poster board and "installed" them taped together to make the full piece "installed". After I was happy with my template, I cut my headliner board to fit from those assembled pieces. It worked great fo me.

The one thing that I never could do is to get the cardboard to conform into the deep bends it appears it needs to have at the sides just above the driver spot and passenger spot. I finally realized that it can't and isn't supposed to conform fully to those bends as long as it slightly bends and overall conforms to the basic configuration of the top of the truck cab. The other thing I didn't take advantage of was the screws that are supposed to screw through the headliner and into the bow that is secured in place form the top of the right door frame to the top of the left door frame. The headliner stayed so well in place and conformed so naturally to the roof of the cab that when I started putting a screw into the headliner, it acturally started stressing it out of shape. So I left it alone!
I've read about spraying with ammonia water and that sounds like a mess, plus you need to have some good ventilation working with ammonia or it can get tough to breathe. BE CAREFULL!
Finally, mine has been in for twenty years and still looks good. I even added radio speakers in it right at the back over the driver's and passenger's head.
This may not be what you want to do, but it worked well form and I thought I would share the procedure with you. Good luck!
Joe
