I'm already in the position where the car isn't economically sound for me, because I drive less than 10,000 miles per year. The Signature is slightly overpriced as it is, anyway. The Standard would require even *more* custom work to get rid of the polyester. Tesla has a monopoly on service, and non-warranty service carries expensive Ranger fees.
So if Tesla is also intending to give me hassle about warranty, which is what it sounded like, then it's just not worth the trouble. The "Tesla Experience" turns into a very substantial additional *cost*. With a typical car I might not worry about getting hassle from the manufacturer because I could just have any local shop do any work, and with a typical car, headliner replacement is fairly straightforward. Eventually there will be electric cars like that, but right now Tesla is making it very clear that the Model S isn't like that. I can't afford to put out $100K on a car which I am not only allergic to, but where it may be impossible for me to retrofit it to not be allergic.
I went to fairly serious efforts to see if I could make this work, but at some point one has to give up!
I have to say good things about the Tesla customer service people; they were very helpful in contacting me and getting me the information I needed. But what they told me was, basically, "We don't believe this car can be made acceptable for you," so I'm not going to get the car unless/until someone else proves them wrong. If someone else replaces the headliner in their Model S successfully, then I can order a model S of a later year (2014? 2015?) and copy what they did. Any takers for going first?
Someone who isn't allergic to polyester can have my polyester-lined Signature slot. I'm sure they'll enjoy it!