When I got my TJ, the sun visors were pretty well shot. Those of you with early 97's know how hard it is to find replacement visors (relatively cheaply anyway). I'm 6'3", so I normally don't use visors in other vehicles because I don't need them. Not so in the Jeep. After looking at visors on Ebay, I found out how expensive they are and there appears to be quite a few people looking for them. The bidding was already up to 50 bucks for one visor, with 16 bidders and 2 days remaining, so I decided to see what I could come up with.
I started thinking about tinted Lexan. If you've ever priced the Lexan visors online, you know they're not cheap, so I decided to make my own. What follows is a quick and dirty smoked plexiglass visor I made. Plexi, because a guy I know across the street has an old school bus and I remembered they have a smoked visor in them. I was hoping they were made of Lexan, but they're plain old Plexiglass. Oh well, it'll work as kind of a "proof of concept" mod. The visor was cracked, so I only had enough to do one side. Later on, I plan on ordering some tinted Lexan off Ebay and doing both sides.
Anywho, on to the mod...
In my excitement, I didn't get a pic of the visor before I taped it up.
Here's what I had to work with:
I had the cover off the old visor, so I laid it out on the plexi to see how long I needed to make it.
Marked it with pencil and used a jigsaw with a metal cutting blade to cut it out:
Here's the new visor freshly cut out:
I rounded the corners with the disc on my bench sander. (sorry, didn't get a pic)
Here's what the stock visor looks like with the cover removed:
It's basically a piece of cardboard stapled to a metal strip.
I removed the cardboard and marked out 5 holes to mount the plexi. I also cut out a small strip of metal so I could sandwich the plexiglas in between.
Plexiglass isn't that hard to work with if you use masking tape and go slow.
I put it together using 3/16" pop rivets, and gave the metal parts a quick paint job.
Now, for the finished product. Please overlook my cracked windshield
It really does a good job at cutting down glare.
Even with the sun shining directly through, it is tolerable.
Here's one more shot of it.
The bus was old and the plexi is a little scratched up, but it does the trick. It's a definite improvement and will work until I can get better materials to work with