So as usual I was delayed by unexpected complications; this time it was the truck not starting. After some help from the forum and a few evenings of electrical diagnosis, got her figured out and running again.
Then back to my custom interior fun stuff!
My initial idea was to leave the foam on the upper portion of the visor to disguise the swivel bracket and hardware. I trimmed the foam down everywhere else to slim the visor down and make finishing the edge easier.
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Yuck. First prototype not successful. It ended up coming out a little lumpy in spite of my best efforts, and oozed enough adhesive through the holes that there was no way it was going to look right. It might have worked with a plain black vinyl, but I want these to match the headliner.
Onwards and upwards! I have another 3/4 yard of this stuff to play with, and I'm too stubborn to quit here.
Second go, I laid it out a little differently. Cutting a groove in the centre foam of the sheet to allow the fabric to wrap tightly around the top of the pivot arm, and trimming back 3/8" of foam right at the edge to make the edge banding slip on more easily.
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A generous amount of contact cement later...
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Very happy with how this turned out. I had a bit of difficulty fitting the edge banding in place and had to stretch it's internal metal "teeth" to make it fit. I'll give it a pass with the sheet metal bending pliers to give it a solid and even crimp.
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This is what it looks like in the truck. Works like it's supposed to, and looks good to me. Now just have to do the driver's side to match. Should go faster now that I know what I'm doing.