Originally Posted by aeroplan73
I would appreciate any suggestions, even if they involve repair techniques.
You can recover the stock board, but you have to address it'* issues too.
GM chose to make it'* headliners with a pressed fiberglass "fluff". Works great for a few years, but the glue that holds it together breaks down over the years, as does the foam backing on the fabric. Cigarette smoke seems to accelerate it.
If you can't find a replacement headboard, you can make one using what'* left of the original.
Take it down, carefully, and peel off the fabric and foam. Use a wire brush to scrub off the foam stuck to the board.
Use can use pieces of cardboard and staples on the back of the board to reassemble any tears in the board. (do it on the back, it'* only temporary)
Next, fiberglass the original board. A few layers of 2oz cloth and plenty of polyester resin will create a new headboard right on top of the old one. Once the front side has cured, flip the board over and do a few layers of fiberglass on the back (remove any patches you do to hold the original together, you don't need them after the front side is done.)
After the board has cured all the way through (give it a few days in a warm enviroment) you can sand the board down and either paint it or cover it with new fabric.