The foam is never good.. it's actually what makes the headliner go south in the first place or should I say go down in this case.... Cheers Dyna
OR!!! Get some thin mahogany or balsa wood and use the old one for a pattern, like the old pre-50's wagons. If you sound deaden it, you could have a rolling boom-box! Never need Q-tips either - it'll melt the wax out of your ears! In newer cars, the side moldings are secured to the roof frame, so with a bit of help from a local school woodshop, you could bandsaw and router your own moldings and just run the panels to the frame perimeter and the moldings for finishing the edges. Hand-built Chevy woodie - inside and out. Forgive me, but I always think outside the box.
Look in the gallery for some of the 1940's woodies and see how they fit the wooden headliners to the door and roof moldings. It's not as hard as it looks. Heck you could really pimp it up with brass chandeliers for dome lights. But seriously it's not hard.