I am in the middle of replacing the headliner in a project 88 744Ti. I have removed two boards and both times they ended up damaged around the sunroof motor opening and the front two corners. This time I have all of the seats and the console out and still managed to do a little damage. I have repaired those areas with fiberglas matt and resin.

The plastic strip on the front and rear of the headliner slides left or right to come loose. I broke some clips getting it out because I did not realize that and now am waiting for the new clips to arrive from Beechmont Volvo.

Try to vacuum up the old foam goo balls that fall everywhere before you press them onto the surface they land on (including the floor of your workspace) They make a real mess.

None of the JoAnne Fabrics in my area had any 1/8" material I was able to get a trim shop owner to order me a roll.

I found the easiest way to remove the sun roof was to take it out of the pan from the back after removing all but the front fastners and letting it hang from the rear drain tubes after they were removed from the hooks. That way you don't have to fiddle with adjusting the sunroof when reassembling (assuming it was adjusted properly when you started).

Randy