Sun Visor. First Attempt, Improvements to follow..

[wizard124]

The original visors were aged and the interior foam deteriorated:


Using the original frame, I gouged out some foam board, inserted the frame, then covered with self stick foam. The foam board (3/16 inch thick) and foam sheet is available at crafts stores.



The vinyl, I purchased at a fabric store. My intent is to use this same pattern for the upper door panels for a coordinated look. Gluing, wrapping the hem, and clamping was a timely, multi-step process. I used a razor blade to trim the hem in the corners where it had bunched up.


The finished product:


OK, now for some self critique Not as nice a product as I had hoped. Better than before but room for improvement. I think the foam board and foam sheets offer a functional base (Does any one else have a better suggestion ) The seams show through and are too distinct. The clamp marks haven't relaxed.
The driver's panel will be done a little differently. I will wrap the foam sheet around both sides of the board and extend the ends slightly longer so they stick together and taper off beyond the board edge. I'll glue the vinyl without the the wrapped hem. The foam sheets and vinyl will be trimmed together, leaving an edge about 1/4 inch thick.

[azruss]

I've done a bunch of upholstery work and what you are attempting is very very difficult to pull off. Anytime you overlap and glue a seam, it will show. I like your idea of extending the edge and gluing it. the secret here is to get a perfectly straight glue line. good luck on that. I had the idea of taking a small tube or windlace of some sort to put on the edge as a finisher. this will hide your glue seam. Good luck with the next one.

[wizard124]

I've done a bunch of upholstery work and what you are attempting is very very difficult to pull off. Anytime you overlap and glue a seam, it will show. I like your idea of extending the edge and gluing it. the secret here is to get a perfectly straight glue line. good luck on that. I had the idea of taking a small tube or windlace of some sort to put on the edge as a finisher. this will hide your glue seam. Good luck with the next one.

Yes, it is much more difficult than I expected it to be. Yes, some rookie mistakes.
The latest test: Trimming a single edge by cutting the foam and vinyl together. Better, without the visible seams. I think I'll try extending the vinyl beyond the foam for a double tapered finish.

[joelittel]

What about using your foam core board/original frame to create the "base" and then spray mounting a thin sheet of additional foam (as thin as possible) to either side of that. Pay special attention to how you cut/shape the foam core board and the thin layers of additional foam around the edges of your "base" because this will play a big role in how your final product looks once covered with vinyl.

Cut the vinyl pattern, two pieces per visor - front and back, large enough to fold the entire edge over on itself and stitch down. Put a finished look on each side by using a sewing machine to stitch a relatively straight cuff along the entire edge. Meaning, you should have two halves, font and back, both with an edge folded over on itself creating a seam like at the cuff of your jeans (the fold goes to the inside and hides the cut).

This will be difficult, especially along the curves.

To make smooth clean stitch lines along the curves takes skill and creative use of small cuts on the inside of each curve. A hair dryer helps motivate the vinyl to bend or flex without buckling. Rubber cement (only along the edges, not in the center of your pieces) helps hold down the folds while positioning the vinyl. Once each side is stitched you can cut off any extra vinyl to make a clean surface for glueing the two sides together. Keep in mind that once you've glued the two sides together any extra material, foam or vinyl, will create bumps and contours along the seam of the finished product.

When putting it all together Shoe Goo works really well, it's flexible and long lasting. Plus, you do not need much. Run a bead of glue, the thickness of thick fishing line, as evenly as you can along the stitches on the inside of each of your vinyl pattern pieces. Sandwich your frame between the two pattern pieces and pinch the edges together with as many clamps as you can. Those black alligator clamps found in office supply stores work well, but use as many as possible leaving little or no space between clamps. This will help evenly distribute the glue along your seam and reduce noticeable blemishes.

I've been "improving" and "redoing" my visors over the last few winters, and getting better and better with each attempt. I have yet to make the foam core base described at the beginning of this topic, but the next time I "improve" my visors I will be doing just that and I'll take photos of each step along the way.

[wikkid]

Could you start from the foam core base idea on the frame, then form the visor you want in fiberglass? There is texture paint you can spray on that folks have used on dashboard restorations that would give you a black vinyl type interior look, but you would have a strong, rigid visor.

[wizard124]

I really appreciate the inputs. Seemed like a simple job at the time

Joelittel: I think I follow you. I know your suggestion would lead to my disappointment. The cuff in the corners/curves with the vinyl bunching and trying to do 2 identical pieces and then glue them and have the edges match. Well beyond my skill set and patience.

wikkid: The textured paint is an interesting idea. I've done some fiberglass work. The resin runs and gets everywhere. I think it would be difficult to keep the resin from getting into the pivot areas of the metal frame. Additionally, the fiberglass mat shows through, so multiple coats would be needed to get a smooth surface. I am also thinking the fiberglass (if I could do a nice product) may be too heavy and the pivot points not be able to hold the visors tight.

BTW, I tried the double taper that I mentioned earlier. Difficult to glue and clamp and it didn't look very good.

[fiat218]

Buy new ones

[wizard124]

Buy new ones

It may come down to that I'm not ready to give up just yet.....

[kbee00]

don't buy new ones just yet- I am in the same position and would love to find out how to refurbish mine. sometimes you buy new, sometimes you find a way to keep what you have. and for some reason, I want to keep my originals too.

I split the passenger visor along the seam top and bottom -pulled out the old crap and the mirror. before I fiddled with the new stuffing I am trying to figure out how to reattach the two pieces back together again. I tested several glues - nothing held. I haven't progressed beyond that.

I would be glad to try another method - any thoughts?

kbee00

[Flyingthere]

Another, unqualified thought, have you thought about making a front and back independently, wrap and glue then glew both sides together?
Just a thought.

[fiat218]

Buy new, move on to something worth while fixing

[kbee00]

Flyingthere - not sure I follow the wrap and glue and then glue back together - could you explain that in a bit more detail?

I am attempting to re-use the original vinyl/plastic pieces. Mine is currently split into two pieces - split at the original factory seam.

Thanks for your input. If we figure out a way to refurbish old visors I think others will join the party.

kbee00

[Flyingthere]

Sure make a front and a back. That way you can sandwich the frame and hide it but you can attach your material to each side independently. Wrap the material over the edges and glue in place on each piece then glue both pieces, front and back,together.
Hat way you would not have any visable glue points and the joints, potentially would be smooth.

[kbee00]

Bob - I feel like an idiot - I can't quite follow what you mean.

I have split mine along the outer edge -all the way around. So now I have two separate pieces. I think they were heat joined at the factory and then trimmed to remove any flashing. Anyway, I haven't found a way to attach them back together again without the edge seam looking like it was cut apart.

Could you diagram what you mean? If it's easier to scan and email to me, I will post it on this site so everyone can see your idea.

Thanks for your patience!!

kbee00

[Flyingthere]

No prob let me draw something up and share via email