I recently successfully repaired/reinforced the visors on my '01 Sahara and thought I'd share. The OEM visors are fairly expensive and I wasn't about to buy another set... knowing they would eventually fail in the same places.
I am a knifemaker/sheathmaker by hobby so I have leather-working skills but the hinge reinforcements are very basic leather work if you've ever used a sewing awl. I patched both sides of each visor (4 patches) during a snowy day here. They've been holding up and working really well!
Leather - I used thin Deer hide but Pigskin should function equally well. Needs to be fairly thin/flexible leather.
Gorilla Tape - Optional but holds everything together while working and provides a little extra reinforcement under the patch.
Sewing Awl - available from most hardware stores
Drill press - Needed to pre-drill the stitch holes in a uniform manner
Stitch Wheel #6 - Optional but will greatly ease in the spacing of stitch holes prior to drilling
Carnuba Creme - Essential to protect the leather
Leather Sheen - Optional but highly recommended
Oil Leather Dye - Optional, I did not use it on the hinge reinforcements... wasn't concerned with color match
Here's what I repaired on both visors. I'm sure some of you can relate.
Gorilla Tape on patch areas. This was later trimmed to conceal under the patches.
The rest is leather sewing which is a bit lengthily to explain and I'm not going to cover it... BUT... basic awl skills and the above mentioned tools (drill press and stitch wheel especially) make it a breeze. There are many youtube tutorials for leather sewing techniques.
Here are the results
Sewing Awl, and stitch wheel
Then I got bored and made a visor pouch for the driver's side. Officers always appreciate it if they can see your hands when they pull ya over. I sewed it directly to the visor. This was much more involved with heavier leather, welts, dye, other leather tools, etc.. I won't get into that. This pouch took a couple of days. The wolf paw is the makers-mark I use on my sheaths and threw that on for the heck of it.