[DanTwoLakes]

Here is a simple project. These are sun visors out of a 57 Chevy. In the first pic I drew out a rectangle on some chipboard and drew in three lines, one in the center, and the others 1/2" on either side of center. I later added two more lines in between so there were 5 lines 1/4" apart. These are used to fold the cardboard around the inside of the visor. Then I drew out the shape of the visor and cut out a pair of cardboard blanks. Because the vinyl has perforations in it, I painted the cardboard blanks black.

[DanTwoLakes]

Next I glued the fabric to the cardboard ( I used foam glue because the edges were going to be sewn down, but you can use contact adhesive if you want to). I cut notches at all the round corners so the vinyl doesn't bunch up. Then I glued the inside of the sun visor to the cardboard, also with foam glue, folded the cardboard around and sewed it down. Here we see a finished sun visor which has been sewn using polyester 138 thread. If you need to, turn the hand wheel on your sewing machine by hand one stitch at a time to get nice even stitches. I use a right single toe upturned foot on my sewing machine to avoid any contact with the masonite inside the visor.

[horvath]

THANKS, Dan!

I just happen to have a pair of sunvisors that need the whole deal you just posted done to them and I've been wondering how I'm going to go about doing this.

You don't show what your brackets looked like before covering them, so I'm wondering if this tutorial will work with what I have. Take a look at these brackets I have:
See Here

I've already covered the bracket-ends with black elk, using High-Temp spray adhesive and I'm real happy with the way that turned out. But ... see the *flat* pieces that turn on the long shaft of the brackets? They are pretty hard to move, as they are. I've lubed them up with penetrating oil and they're moving smoothly now, but still pretty hard to turn by hand -- maybe that's because, without the visor on them, there's too little leverage?

The "*flat* pieces that turn on the long shaft of the brackets" *do* come off easily enough. Originally, Chevy just staples cardboard to them and that's it!

So ... help me out here. Do I get rid of those or do I use them?

And, PS -- What if you wanted to sew some pockets on one side of the visor? You know -- to hold papers, etc.

[DanTwoLakes]

Alan: The process I described will work with most any sun visor. If you look in the upper left corner of the second pic in my first post, you'll see what the original bracket looked like, and that same picture has a drawing of the shape of the masonite. Yours will work, but you need to attach some masonite( or any other thin,sturdy material) to them to support the cardboard, and also for leverage to be able to fold the visors up and down. As cheap as aftermarket sun visors are, you might think about just replacing them. (I'm talking about the ones that aren't upholstered yet.)

As far as a pocket goes, just sew on whatever kind of pocket ( or even just some elastic strips) you want to the fabric or leather blank, center it on the cardboard as you're gluing the fabric down, and assemble as shown. If you are going to put a pocket on, I would definitely do all my gluing with high temp contact adhesive so it doesn't pull away from the visor.

[Jagman06]

Two Lakes; Your detailed instructions have been very timely for me, thanks. Stupid question though; Where can I buy chip board?

[DanTwoLakes]

Not a stupid question at all. You can buy cardboard (chipboard) at www.uline.com, or go to a printing place, they use large sheets as backing for tablets. I buy mine from one of my suppliers, but it's getting expensive. They make me buy 50 pounds at a time, and it costs $80.00. For patterns, I use 30 thousandths thickness For the sun visors I used 40 thousandths thickness.

[Brian_B]

That is quite interesting. The PO put some in my truck out of something. He spray dyed them black. They don't quite fit, but they will do until I can get the correct ones made.

At least I know how the upholstery shop will make them now.

[302 Z28]

Dan, great work as usual. Keep posting your work, we all need the tips.

Vince

[Travis Byrne]

First off would like to thank Dan for doing these. The above visors are for my 57 Chevy 150. Dan has been a life saver. He made custom windlace for my car and now he has covered the factory visors to match the new headliner in my car. There are no local upholster shops where I live and have had a hard time of getting things done for my car. I am on a real tight budget and have had this car for some time now. I don't ever plan on it being perfect, but would like to have a nice 100% driver car and Dan has been wonderful in helping in the interior of my car. I am a person who loves to do as much as I can on my own, but some things are just better left to the professionals. If you want good quality work done on something, send it to him. I am trying to figure out how to get him to come to Corydon Indiana and recover the 90 Beretta bucket seats I have in the car to match the black and white diamond tuck I have on the door Panels and rear seat.

Again thank you Dan, you are the best.

Here is e-mail I sent Dan:

Wow!! They look great. You have to be one of the most talented upholsters there is. Would you move to Corydon Indiana so I can get you to do some other work that is to big to ship to you? I have to find some place local to have my 2 buckets recovered to match the rest of my interior. I have door panels, rear side panels, and the back seat out of a 1955 Chevy 210 in my car. It has been done in a black and white vinyl, with the white being diamond tuck. I have installed bucket seats out of a 90 Berretta and they just do not quite match. It still looks good, but I would like to get the front seats done to match the rest. I will try to get some pics and send them to you so you can see what your work is going into.




Quick history on car.
1957 Chevy 150 6cyl, 3 on tree.

Now
283 375hp
Saginaw 4 on the floor
210 55 Chevy Black and White interior
Bucket seat in front
New Carpet and Headliner
30yr old Black and White Lacquer paint
Anes steel chrome wheels (look like Crager SS)

Will be installing an electric dual fan kit soon and new front springs

Need new chrome all the way around, but that will take some time.

[302 Z28]

Hey Travis, I would like to echo your comments. Dan did some windlace for my 34 project that was terrific. When and if things slow down at my house and I am able to divert some time to my 34 I plan on sending him some floor mats to sew up. Now with his latest post I am considering sun visors for my 34 which I haven't even thought of.

Vince

[DanTwoLakes]

Thanks, guys. I'm glad you all like the posts and the tips.

[Rusty 35 Ford PU]

Hey guys,
Lets all chip in $, buy Dan a van that....second thought, an RV that has all he needs to come around and help us out?!!!???!!!
Send all the $ to me and I'll take care of it?
Seriously, Thanks Dan for the posts.