Sun visors - reupholster or buy "new"?

[Emily Koch]

I can't seem to find that part anywhere, either! Your best bet might be to find one from a visor that isn't in great shape. I've used Retrobrite to brighten the plastic piece on them when they're discolored.

 

Also, an update! I finished my experiment on replacing the foam, and I think it went alright! Here's a blog on my process if anyone's interested.

[Lucky 7]

Same problem here. I also wanted the visors to match the new perforated microsuede headliner I’m putting in, so reusing the original covers wasn’t an option. The upholstery shop method involves a sandwich of fiberboard and new fabric, then the whole thing gets edge welted. It’s what they did in the Clarion car. Not terrible by any means, but doesn’t look very original IMHO. 
 

I knew I’d need to fabricate a new visor. After much head scratching, I decided to copy the modern method of fabric wrapped plastic halves glued together over the frame. 
 

I started with 1/8” expanded PVC foam sheets.  Two sheets were laminated together to make one 1/4” thick half, one sheet gets a cutout for a mirror:

 

My original visors hit the rear view mirror, so that’s why the frame is…ummm, massaged a bit.  Then the sheets got glued together with PVC cement to make two 1/4” halves. I cut each half to shape, sanded the outside edges round, and cut out channels for the frame to sit in. Pain in the ass, you ask?  Why yes, yes it was. Eventually I got it to fit though. 

 

Then it was spray adhesive for the fabric covers and lots of trimming, super glueing, and taping to get the edges down.  

 

I did black vinyl and a mirror on the back half to give it the OEM character.  Then the two halves got glued together over the frame. 

 

After sitting for a day or two under 50 lbs of dumbbells, they were all finished. 

 

I’m really happy with the result. They look great, they clear the mirror, and they’ll match the new headliner. I worried the entire time that they’d turn out like Homer’s spice rack, but they actually look pretty legit.  Maybe it cost me $50?  Lots of work, but it was a fun little side project. 

Edited November 5, 2022 by Lucky 7

[Rich]

Lucky 7, GREAT job, nicr instructional post,