Awhile back I attempted to fabricate a fiberglass headliner for my 56. I used the top of the roof as a mold and laid up some fiberglass on it to get the proper curvature so that I could place it on the inside of the roof panel as a headliner. It was a learning experience at best...let's just say that it has yet to be completed.
My next experiment involved ABS plastic. I bought a sheet and thought that it would be easy to heat it with a heat gun and shape it to fit...wrong! What a PITA.
I have a book on automotive upholstery written by Taylor & Mangus where they demonstrate how to make a headliner using layers of chipboard (heavy cardboard). It seems a bit tedious but the results are impressive. Has anyone else taken a shot at fabricating a headliner for their truck? Also working on a deck lid for my 40 coupe...it's a little easier to handle than the roof of a truck cab but just as challenging.

 

I have to agree with you on the ABS......very difficult to work with.
Here's my headliner thread, might give you some ideas....

https://www.ford-trucks.com/forums/1...headliner.html

 

Thanks Scott...I had just gotten back from HD with a sheet of Luan plywood when I read your post. Seeing how the ABS reacted for you reminds me of what I have been seeing on my project...lots of puckers. I will still be using the ABS for the side panels, etc where there isn't so much forming needed. I may layup some fiberglass over the Luan when/if I am done just to make it more weather resistant.

 

Charlie you might try a pm to gangstar ( Robert ) on the slick forum he has a very nice interior if I remember correct including the headliner it's a 65 but may give ideas
It's a Yblock theme so it's not a65

 

ABS is no good, but you can buy PVC board from a sign shop that bends quite easily with a heat gun. About 20 bucks for a 4x8 sheet. No matter what you do, the headliners in these trucks are a pain to do. My roof had to be strapped with strips of plywood to give it a structure to attach to.

 

Charlie. This is a very timely post. I just asked yesterday about headliners. I will read thru the post and mayby attempt a headliner