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About a year and a half ago I fixed the drivers side visor, but didn't document it.
The passenger visor has been loose for some time now and I finally got around to opening it up and documenting its repair, enjoy.
After cutting the threads around the perimeter of the visor this was what I found.
I used some pieces of aluminum as my stiffeners. I made them 1.25" wide by 4.5" long. I cant tell you where the aluminum came from but I can tell you it had green reflective tape and white reflective letters on both sides , its been in the shop for about 10yrs now. With a wire wheel on the grinder I removed the reflective tape from one side.
The visor had 4 staples that went through the two metal sides of the hinge and through the fiber board. They were not much fun to remove due to their thickness. It took white a bit of prying and pulling with different tools to remove them without doing any more damage to the visor.
The staples left behind 2 holes each that were 1/2" apart. I drilled out the holes so I could pass the stainless wire I had through them. Remember to place something on the other side of the metal hinge to prevent your drill bit from poking though the fabric of the visor.
I drilled two holes (1/2" apart) in each of my aluminum stiffeners & bent a 3" piece of stainless wire to go through them.
After passing the stainless wire through the metal hinge and the aluminum stiffener, I twisted the wire tight.
This is what you'll be left with once you do all four.
The holes in two of the stiffeners will need to be positioned so that the stiffeners don't lay on top of the vanity light. You will also need to trim the end of those same stiffeners so they lay flat on the metal hinge. Remember to cut off the excess wire and lay the twisted section down the best you can.
Now a very generous amount of super glue beneath each, a few clamps and your visor is no longer FLOPPY. Don't tighten the middle two clams so tight you break the mirror or the plastic cover. Just tight enough to get the stiffener to set flat on the fiberboard and engage all the super glue.
I did this last night and left it in the shop to set up. I tried to sew my last visor and gave up pretty soon cause it was a PITA. I brought the visor to my local upholstery shop and they sewed the edge up for me. I'll do the same with this visor and in a day or so it will be back on the car.
I'm certain that the superglue works because I performed the same procedure on my drivers visor over a year ago and its still going strong.
I don't recall seeing a NEW visor for $50 anywhere.
What's to keep a new visor from breaking like these have?
This fix didn't cost me anything but time...
I replaced both of mine, they are much sturdier that the stockers and the door that opens and closes is better too. Time is time, if I'm fixing a visor or making the money to buy it, it takes about the same time and I have a fresh NEW visor in the end.
I'm rebuilding mine and the masonite isn't broken like yours, yet. I coated the masonite with epoxy to strengthen it and keep out any moisture in the future.
I'm rebuilding mine and the masonite isn't broken like yours, yet. I coated the masonite with epoxy to strengthen it and keep out any moisture in the future.
I was thinking about doing the same thing to mine. I have the "floppy ears" syndrome on both of mine at the outer ends of the mirror near where they attach. I can feel the the particle board material inside is broken so I need to figure out a way to repair that as well as epoxy the rest of it to reinforce it. How are you going to stitch them back together?
Either with a sewing machine or by hand, I've got some black Alcantera for the outside and 1/32 thick Lexan to replace the cardboard that's disintegrating.
Fixing Broken (Floppy) Sunvisor
, its been in the shop for about 10yrs now. With a wire wheel on the grinder I removed the reflective tape from one side. 
