Redundant perhaps, but maybe can help someone else. Removal of the visor is quick and somewhat simple thanks to prior threads. Popping out the vanity light could even wait until the visor is removed from the car although the benefit could be to lighten up the works.

I wanted to do as little damage to the upholstery as possible. Prior repair descriptions speak of using mechanical fasteners like screws or rivets but the plastic frame is thin and the covering isn't thick enough to allow for a margin of error IMO.

The first plan was to use JB Weld on the thin edge of separation and layer it on along the frame to support the bond.

cured for 24 hours and eagerly installed the passenger side. Flipped it down and...CRACK. On to plan B.

After a search through my hoarder stash of hardware I found 1/2" flat head brass screws in a pack of hinges. Drilled 4 holes along the edge thinking there was enough meat at the bottom edge for the screws to bite into. Wrong again.

Plan C is now curing with more JB Weld. I cut thin strips of aluminum from cat food cans (appropriate for the big cat?) And applied them along the inner edge and clamped. The left side didn't need a clamp to hold closed as the original plan A was holding. The aluminum shim was added insurance there. Photo below, successful report hopefully to follow. BTW, uncured JB Weld can be cleaned from upholstered material with isopropyl alcohol.

 

Update, neither held. Not drooping as far but still giving that cracking noise when flipped up and down. I may try Chicago screws in chrome finish next, drilling through the plush outer material and the plastic frame. Clamping it tight and installing four on each visor to hold that sandwiched tightly.

it seems that the greater force is supplied closest to the pivot arm.

 

Lots of force on things with leverage. Making things 'better' some times makes things worse. My old cars had a steel rod with cardboard wrapped and stapled around it. Worked for decades.

 

Following your repairs as I have never found anyway to properly fix these? I eventually break down and pay the high dealer price to replace them.
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