[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.