I started out the same as before by cutting the visor shape out of foam board, gouging it out in order to lay in the wire frame.
Then, I folded over 2 sheets of thin self-stick foam. I had to insert a wedge of foam sheet since the I didn't get the 2 sheets perfectly square. Fill the cracks with extra adhesive:
Use a putty knife to smoothly spread the adhesive over the entire foam surface to glue the vinyl.
I glued 1 side at a time. I sandwiched the visor between folded towels and weighed down with books:
The visor comes out looking like this: Use heavy duty scissors to trim to shape. You are cutting about 1/4 inch of foam sheets and vinyl.
I bought some 1/4 hem to trim out the edge. Sorry about the focus:
The finished product
Not flawless. But a result I can live with. Now to re-do the passenger's side 
A couple of things: I used a black sharpie to blend in the white backing fabric of the vinyl. This made the visor look a lot better, even before adding the hem. The cost of doing this is pretty cheap. 5 foam sheets at about 1 dollar each. The foam board was about $5. A tube of glue $6. The hem $1.50. The cost of your vinyl can be $10-30 /yard. A couple of hours of your time (assuming you avoid having to do it twice
)The satisfaction of your own handy work....priceless
