The fabric on my roof cover trim (above the doors) was falling off on the driver's side, so I took both sides off to have them recovered. While removing the one on the driver's side, I pulled back a bit where the overlap is, and the piece cracked in half right down the middle.

Before I buy a new piece, I was thinking I could use a piece of metal to bridge across the back and join the two with pop-rivets on each side. The metal would be in the crevice and unseen, and the new fabric should cover the head of the rivet. Wondering if anyone has run into this before and whether or not it would hold up, or if I just need to cut my losses.

 

Not exactly, the piece above the door (think the B piece) left the tab behind (these things are quite brittle)..I didn't repair it as the next piece overlaps it to hold the back end in place. I was taking down the roof liner to replace it.

I would think you could use epoxy and fiberglass on the back to hold it together although that might be more expensive in materials than a new piece if they are available.

 

Same piece as mine. You lost the tab which would have made it more difficult, whereas mine is split down the middle.

The dealer wants $300 for a replacement. I can buy one used for $100 and then re-cover it.

Were you thinking something like Bondo Fiberglass resin with a extra patch across it?

 

Ya something like bondo and a mat patch (build it up with a few layers). I have regular epoxy resin and fiberglass mat which I used on my sailboat keel.
Do a couple of layers on the back and one on the front.

$100 sounds alright for a used part.