Welcome Carol. I am currently in the process of replacing similar headliner panels
in my cat and would recommend the use of white frp embossed panels
that are available for under $50.00 for a 4' x 8' sheet at Home Depot.
They cut easily with table/sabre saws and can be easily shaved down for an exacting fit with #40 sandpaper. The panels resemble the pattern of many molded frp headliners and, as they are frequently used in the interior
of industrial refrigeration
units, are well suited to the marine environment
You can drill and screw directly into the overhead (through the inner laminate and, obviously, not past the core
material). You can also purchase
white plastic caps to cover the screws at various places (and quite inexpensively at Boat Parts At Surplus Unlimited. Boating accessories, marine supplies, trailer parts, gauges. We specialize in Teleflex & SeaStar steering.
under the heading 'other fasteners'). In fact, they are also a good source of inexpensive s/s screws for the project
. I would recommend nothing longer than 5/8" flat heads.
Plastic molding is available for seams, although I find a better finish by taping off about a 1/4" on both panels and using white, GE bathroom silicone. Pefect colour match and easy to remove/replace when you need to get at the wiring
Alternatively, if the plywood
is still in good shape, you can always attach the frp panels over the plywood
resin, or available at Home Depot, buckets of FRP panel adhesive
that one puts on with a trawler
. This will keep the curve without so many screws (although it will certainly add weight).