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I am in the process of getting my 65 back on the road. Before I let it sit up the headliner was in great shape but father time eat the thread at one of the seams so now its hanging.
Do I have to have the glass removed to get a new one in.
Has anybody changed out the ford headliner for a cardboard after market one?
 

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I have installed a headliner only with the glass removed. A friend of mine has taken many Mustangs to a local upholstery shop for headliner installs. They always do it with the glass installed and it always looks great. So, I'm not sure if I could do it, but it's certainly doable.
 

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Been done, pain in the butt to get the headliner tucked and tight as it should be with the glass in. The RIGHT way is with the glass out. I can do one by myself in a day and reinstall the glass leak-free. Doing it the other way is not only a "hack" or short-cut, fiddling with the top of the glass seal that much trying to fold the headliner in will either lead to a windshield leak or an incorrectly cut and eventual sagging headliner.
 
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The factory attached the headliner to the pinchweld before installing the glass. There is no way to properly install a headliner without removing the glass, because with the glass installed there is nothing to attach it to. Of course, you don't have to remove the front glass in the 69-73 Mustang.
761173
 

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1966 Mustang Hardtop 289 4 Speed
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I looked at the shop manual before I did mine and was surprised to see their instructions were for glass in the car. I've only done 1 but can't imagine getting a tight fit for that method. Perhaps a seasoned pro could pull it off. It would be a bugger trying to pull the rubber down to get glue and the headliner tucked in neatly.
 
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