So, I would imagine that I can place the earliners in laquer thinner?, for how long should I leave them in? Do I position them before or after they are in the ear and will I need to card the ears/liners?
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I usually cut them to size as gaged by the real cartilage. Then I feather the edges on a sanding belt. Wet them with solvent just so they are damp, fold them as you'd like them to be and when the solvent evaporates, the liner will be in the form you desire. (Note: the commercial, pre-made liners have tabs that are stapled together to form the ear butt and the edges are usually thicker than I like.)
maybe someday I'll be brave enough to try bondo, until then I think I will stick with your idea.