Tony, a good very thin high quality plywood with an 'A" bond, faced with melamine makes a great, durable headliner.

If you want to go retro I have a lovely white shag pile carpet headliner circa 1984 that still looks nice

Regards Don

Donk107 said..
If you want to go retro I have a lovely white shag pile carpet headliner circa 1984 that still looks nice

Regards Don

My mate had a panel van lined with that!

The shower product is called "Lamipanel" and is by far the best product

What about HDPE sheets, comes in most colours and is UV and waterproof. You can buy it in all the sizes and thickness as what you can get plywood in and more. If you have a rounded roof you could go something like 3mm thick and it will easily curve into shape. I done a quick google search for NSW to get you started and came up with www.dotmar.com.au/contact.php and www.tridentplastic.com.au/. Also depends on where you go i came up with 2000mm x 1000mm white HDPE sheet 3mm thick $150 to give you some idea of cost. Or 3000mm x 1500mm 3mm thick $180. www.plasticwholesale.com.au/.

Donk107 said..
If you want to go retro I have a lovely white shag pile carpet headliner circa 1984 that still looks nice

Regards Don

reminds me of a stationwagon I had once.....ahhhh...the memories lol

You could have a look at alupanel. 3mm thick, aluminium composite. Light and cheap. Comes in lots of colours and mainly used for signage.
www.sassignage.com.au/

One word of caution with Alupanel. The black core that has been around for a while is not fire rated and will possibly accelerate a fire if one breaks out. There is however a new white core available that is fire rated and is becoming the standard for all building cladding. There are plenty of distributors around, and there are two versions of Alupanel. The standard premium which has thicker Aluminium and the Alupanel lite, which is a thinner aluminium, but the same sheet thickness of 3mm. We use Sign Sheet Distributors in Blacktown. Sheets come in 2440 x 1220, 3000 x 1500 and 4000 x 2000. Although the colours are usually only in the 2440 sheets. They'll cut to size, and can also rout different shapes if you provide them with a vector file.

You can cut both with a stanley knife if you're cutting a straight line. Score it a couple of times and it will snap. Intricat cuts will need a router or a jigsaw, but it's messy. Do all the machine work outside the boat if possible. There is also edging and sheet joints available from Bunnings that is usually used for the timber grooved panelling.