Hey guys,
Trying to find a new wagon headliner board is like the proverbial quest to find the holy grail. Usually we try to repair them the best way we can, whether it's by using fiberglass cloth. or matting, duct tape, whatever. I do recall a member using a type of corrugated plastic board. He claims to help conform the shape with a heat gun. It sounded like he was pretty successful in achieving that goal.
Mark, I do like your suggestion about using foam board, and again using a heat gun to achieve the shape.
Most guys that have pulled their headliners down found that they were in pretty rough shape. I have heard of aftermarket replacements made from ABS, of course not for a wagon. However, I have heard negative feedback about them. I too would like to make a new headliner board. The rear smaller headliner still seems to be in decent shape. Perhaps we can come together to find a viable solution.
I wonder how difficult it would be a make a form or buck, and mold one using fiberglass cloth, much like building a fiberglass boat hull. I realize fiberglass resin and cloth isn't cheap, but it would be a permanent fix.
Even if someone in another state, etc, had one, it would be virtually impossible to ship without destroying it.