While trying to replace the moonroof seal in my car (3 yrs ago now), I got impatient and pulled the headliner board (didn't know about the screws). Needless to say, I'm on a hunt to replace the board. My kids are forever nagging me about when I'm going to fix it. Well, it's kinda hard to even locate one. Oh sure, if it were a wagon, I might have more available options, but, well, it's not. If anyone out there in Volvo lovers world has any suggestions, please! please! PLEASE! help me.

 

They can be quite successfully repaired from behind using fibreglass and resin. Just take liner out, set it up as it should look (use whatever underneath to achieve this). Peel headliner back in the area you are repairing and apply masking tape to prevent resin leeching into headliner, then repair as per usual fibreglass techniques. You'll probably want to replace the headliner material if you have the headliner out of the car, so you can go crazy with the repairs.

 

Sorry, when old board came out, it was in several pieces due to smaller areas around moonroof, and short temper.
Original pieces are non-existant. New board will be necessary.