Richard, I'll be interested in what you learn about the door cards, as I need to do this on my '71. My plan was to get some "marine vinyl" with the appropriate texture and do the work myself. I would replace the fiberboard part of the door card with my own, as it seems like it's fairly planar except where the 3 door handle screws hold it down.
The only real issue that I see is that trapezoidal accent pattern above the door handle. That would be hard to recreate, but I think the way it can be done is with a precision sewing machine and something called "sewing foam" (I could have the name wrong). The idea is that the sewing stitches compress the foam along the stitch line and it creates a nice pattern.
Or you could just buy the door cards from AR!
For the sun visors, I'm guessing the way these were made originally was they wrapped a foam blanket around the internal wire frame, slapped two big vinyl sheets on the top and bottom, put it in a heated press that had an outline just like the end product, "melted" the two vinyl sheets together at that outer edge, let it cool, and then trimmed off the extra vinyl on the outside of the joint. However, this doesn't help us much here. So, I find used ones every so often that are in pretty good condition, and with some cleaning and vinyl conditioner (Armor All), they look pretty good. If you have a better method, I'd be interested in what that is.
-Bryan
