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lotsa questions... answers in parts:
1) Headliner material or backing board? The former can be purchased at any fabric store for about $50-$80... just measure what you need and ask for 1/8" thick headliner in the appropriate color. If they don't have 1/8" have them order it, don't buy 1/4" instead under any circumstances (it's too thick for certain applications such as the edges near the sunroof opening). In the case of the latter I suggest you try to use your existing backing board by fixing it if need be. Your next best bet is a junkyard, where you may find a complete or better one. Your last option (not really an option) is volvo, who will charge you something like $800 or smore for a new one (I heard over $1000, but I still find this hard to believe).
2) The seal shouldn't matter for the water... it isn't water tight to begin with, and water that leaks in should drain out the hoses in the four corners. If you are getting bad leaks you may want to check the drain hoses to see if they are blocked up.
If it's still really bad you can get a replacement at a junk yard or buy a new one from volvo (I don't know how much Volvo charges since I just found my replacement in a junkyard off an early 90s 700). On a sidenote, use silicon or caulk in the groove to affix it to the sunroof panel, and fill the inevitable crack between the two ends with caulk or silicon as well.
3) If the sunroof doesn't sit right take a look at the 700/900 faq section. There are a myriad number of possible causes, from loose adjustment screws to broken support struts. On a side note, your car is an early design and invariably has the flawed sunroof support brackets and venting design (mine is an 85 and had the same problem... theres a big post about it in the FAQ). In short, this design flaw leads involves the breaking of the support struts and leads to an inability to stablize the sunroof's sitting position regardless of whether the adjustment screws are tight or not.
good luck,
rt
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