NickO as you have probably learned, there are pretty limited choices for pre-formed headliners. The ABS ones generally are made to be covered with cloth or other material. I didn't want that for my truck so I went with a fiberglass unit. I think the installation would be similar for either one.
I am happy enough with the finished result but it is the least well done part of my truck in my opinion. I had 3 basic issues and all could be avoided with better planning and experience on my part.
If you go with a fiberglass unit it is designed to be painted. I had the paint store color match my seat and door panels. I didn't want shiny paint and asked them to add flattener. They didn't seem sure how much to add and indicated that was usually the painter's decision. Anyway, it came out shiny despite the chalk they added to the paint.
My second issue caused the third issue. I had only my wife to help me position and mark the headliner before trimming. I know better then to use my wife but sometimes there is no choice. Even under good circumstances it is somewhat challenging to hold the whole headliner tightly in all areas to mark for trimming with only 2 people. In the end I removed to much material from the side she was holding up and ended up with a gap above the door. I resolved this by adding metal strips above both doors so it looked planned. The metal strips may have been necessary anyway because the fiberglass wanted to curl inwards in this area and only the windlace holds it.
In retrospect, I think this fiberglass headliner may have fit almost exactly with very little trimming if you position it in just exactly the right spot. To accomplish that might take 5 people (4 holding and one marking any areas to trim) or put in in with the cab upside down.
You can see how mine came out here
http://s99.photobucket.com/albums/l...?action=view¤t=IMG_3016JPG.jpgChuck
