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I did my 1987 740 sedan not long ago. The hardest thing was getting the headliner board out of the car. I removed my front windshield, since it needed replacing. I will NEVER do this again, as I am still finding glass shards in my butt.
I got 1/8" headliner, the biggest concern is for the sunroof clearances. Make sure you get the right 3M spray for light trim and NOT heavy duty.
I used 2 cans for the board and another for the sunroof. Because you install the liner on the board in halves, I used 1 can per half. Also, get some 2-sided clear tape from WalMart for when you are installing onto the sunroof hole and sunroof.
When I had my headliner board out, it broke, so I bought a fibreglass repair kit and custom cut cloth pieces and reinforced all of the breaks, corners, weak spots with the firbreglass. It was bullet proof when I was done.
One piece of advice, let the glue dry for a day or so before you reinstall. When you are hanging the board, don't support the weight of the board with your fingertips or you'll have indentions all over. They'll go away evenutally, but they aren't pretty.
Good luck!
Scroll down to the headliner pics. The job actually came out better than it looks in pictures:
http://pg.photos.yahoo.com/ph/jamiebabineaux/album?.dir=81b3&.src=ph&store=&prodid=&.done=http%3a//photos.yahoo.com/ph//my_photos
Jamie
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