Ok, going to try to resurrect this old post...

irate2:
I am trying to replace the headliner in both my '89 and '90. I don't care much for the stock headliner material, and am eyeing different types of fabric to do the job. My wife and I found some cotton-backed vinyl fabric that almost perfectly matches the blue interior of the car(s), and I would like to use it.
My question is this: can I glue the fabric directly to the headliner board, or do I need to find foam to glue in-between? There are many forums based on the question of custom headliner material, but none seem to address this question.
It seems that the heavier material might cause the glue to stress and the headliner will fail prematurely. Using no foam would negate this effect (as it is usually the foam that fails), but it is possible the gap resulting from lack of foam would be noticeable around trim and such. On the other hand, since vinyl is non-porous, the vinyl cloth could certainly be glued to foam easily with the same spray-on adhesive as the headliner itself, without glue coming through as in regular material. Also, if any repairs were made to the headliner board itself, these repairs might be noticeable if no foam is used.
I did find some cotton backed vinyl at the fabric store which had a thicker cotton layer (1/8" perhaps), but they only had one color, and it wasn't the one I wanted.
ANYWHO, hopefully y'all can shed some light on the subject.