rcfryer wrote: If the original board is missing, you can use the sunroof for support in the center of the headliner and just glue the edges under the roof surround moldings. The easier way to do this is to glue the headliner in around the edges, then mount it to the sunroof frame.
This appears to be what the previous installed did. Either he used bad glue, bad technique or bad products but the around the perimeter of the headliner, it has sperated (top cloth like layer, and something similar looking to a filler layer). Around the sunroof, it is anything but attached right now. It looks as if the installer attempted to glue it to the sunroof frame, but that did not work. I have it tucked into the frame so it doesn't dangle on my head.
Would I be able to make a new shell? say cardboard, or plexiglass? (brainstorming out loud. Trying to come up with a thin light material.)