Replaced headlining with curtain material
Fantastic thread, had this problem in my VS so thanks to Coiners and all contributors for the handy tips.
Here are a few before/after pics if anyone's interested.
Couldn't be bothered stuffing round trying to install a layer of new foam, couldn't see much point having any and the car hasn't felt any hotter or colder than usual without it. I used all of a 1L can of Selley's Kwik Grip to directly glue curtain material to the cardboard once I'd scraped off the old foam. Glued it on in three stages, starting at the back and finishing with the front third of the cardboard section. No paint rollers used, just smoothed it out by hand from the inside to the edges. The glue did not come thru the material and was easy to apply to both the cardboard and material using a wide paintbrush before sticking them together.
Originally planned to do this on the cheap but then saw Warwick brand Luminous Colour Onyx at a curtain specialty shop in Melbourne, this meant an additional $25 small orders fee (it's normally bulk ordered to make household curtains) but I really liked this particular material, which has a metallic sheen and wanted to go a darker shade than my original velour, so was prepared to fork out the extra $$.
All up $110 for the material, $20 for 1L of Kwik Grip from Bunnings = $130. Still beats $330 at a professional upholsterer and at least I got a new look for the interior that I really like, instead of just more stock standard velour. Was late and poor light when I finished so the last pic doesn't do enough justice as to how good it really looks now! In one pic, I just noticed the headrest not is looking too great, might have to do up the seats next...
CK