Sun Visors - DIY
Thread Starter
Moderator
iTrader: (11)
Joined: Mar 2002
Posts: 12,604
Likes: 7
From: East Central Florida
Sun Visors - DIY So one of my visors broke inside and the other is looking
kinda lumpy. I went to the junkyard and every car had
already had visors picked, or the visors were even worse
shape.
I have just gotten a box of 1/16" ABS plastic sheet with
grain on one side, to try and cobble up a replacement
pair. I'm going to thermoform over a 3/16 welding rod
and see how that goes. Hopefully it won't look asstastic.
I'm not that fond of the fuzzy fabric and wouldn't mind
more black ABS, as long as the color's close.
I'll post some pics when I get something glued up. Seems
like this would be right up 6LE's alley but I saw no such
thing on his site.
kinda lumpy. I went to the junkyard and every car had
already had visors picked, or the visors were even worse
shape.
I have just gotten a box of 1/16" ABS plastic sheet with
grain on one side, to try and cobble up a replacement
pair. I'm going to thermoform over a 3/16 welding rod
and see how that goes. Hopefully it won't look asstastic.
I'm not that fond of the fuzzy fabric and wouldn't mind
more black ABS, as long as the color's close.
I'll post some pics when I get something glued up. Seems
like this would be right up 6LE's alley but I saw no such
thing on his site.
TECH Junkie
Joined: Oct 2009
Posts: 3,551
Likes: 2
From: Rutherford, North Carolina
Can't wait to see the end results cause mine are the same way with the "lumpy" part and I think in one of mine, the "cardboard" (or whatever it is) as started to break apart a little.
A good writeup and price and it would sell like wildfire. Hell if a person could get some ABS plastic sheets about the same width it would be easy to sit down and draw a pattern out and then cut them out. Would be simple to make a few sets from a sheet depending on the size of the sheet and the worst part about it would be the need to sit down and cut out all the pieces lol.
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Interesting plan. My driver side one broke in the perforated part of the cardboard and so it has a floppy corner too. The fabric on the top is really worn out, which is interesting since I never flip them down... I think the fabric may be getting too baked through the T-Tops. I was either going to just buy some off ebay or find an upholstery shop to do it. Now I'll have to see how this works out because it seems like a good idea too.
TECH Apprentice
Joined: Jan 2003
Posts: 333
Likes: 1
From: Jefferson, LA
I'd like to get a set of aviation sun visors. Some of the old Duesenbergs had them. Unfortunately they are very pricey.
http://www.aircraftspruce.com/catalo...osenvisors.php
http://www.aircraftspruce.com/catalo...osenvisors.php
Probably better off searching the junkyard for a sunvisor from a DIFFERENT vehicle with the same style mounts and that way maybe find a better version (like with the extending thing) and then just get it recovered to match.
On The Tree
Joined: Dec 2010
Posts: 111
Likes: 1
I'd like to get a set of aviation sun visors. Some of the old Duesenbergs had them. Unfortunately they are very pricey.
http://www.aircraftspruce.com/catalo...osenvisors.php
http://www.aircraftspruce.com/catalo...osenvisors.php
looks like it could be easily replicated with tinted lexan or plexi glass
Thread Starter
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iTrader: (11)
Joined: Mar 2002
Posts: 12,604
Likes: 7
From: East Central Florida
OK, here we go.
I got done with the driver's side last night. Found some interesting stuff
inside the busted visor (it was floppy for a reason)
The core steel stamping provides the rigidity. It was cracked in two of three
sections. The cardboard core also was broken, not much for that once the
steel goes.
The metal is way too thin to be weldable. But I came up with a scrap-pile fix
(next post)
I got done with the driver's side last night. Found some interesting stuff
inside the busted visor (it was floppy for a reason)
The core steel stamping provides the rigidity. It was cracked in two of three
sections. The cardboard core also was broken, not much for that once the
steel goes.
The metal is way too thin to be weldable. But I came up with a scrap-pile fix
(next post)
Thread Starter
Moderator
iTrader: (11)
Joined: Mar 2002
Posts: 12,604
Likes: 7
From: East Central Florida
I used a spare piece of steel in between the leaves of the core stamping. I
drilled 1/16" holes using the original staple holes as guides. I used a piece of
Pendaflex file folder rack (about 1/8" x 1/2").
Outside of this I sandwiched two 2" pieces of the ABS plastic and re-stapled
the whole thing using 1/16" stainless welding rod cut & bent to fit and punched
down tight.
I trimmed odd the formed ends of the internal spring (that stops the rotation
so the visor doesn't flop) and tucked it back in under the plastic sheath.
drilled 1/16" holes using the original staple holes as guides. I used a piece of
Pendaflex file folder rack (about 1/8" x 1/2").
Outside of this I sandwiched two 2" pieces of the ABS plastic and re-stapled
the whole thing using 1/16" stainless welding rod cut & bent to fit and punched
down tight.
I trimmed odd the formed ends of the internal spring (that stops the rotation
so the visor doesn't flop) and tucked it back in under the plastic sheath.
Thread Starter
Moderator
iTrader: (11)
Joined: Mar 2002
Posts: 12,604
Likes: 7
From: East Central Florida
I formed the outer skin of 1/16" ABS. I cut it to rough length, marked the
center line and balanced it on a piece of 3/8" fuel line with some metal strips
clothes-pinned to either end for weight. Heating it gently from the bottom
with a heat gun made it slump nicely around the fuel line.
center line and balanced it on a piece of 3/8" fuel line with some metal strips
clothes-pinned to either end for weight. Heating it gently from the bottom
with a heat gun made it slump nicely around the fuel line.