Sun Visor Refill, I need some info Options

[jdamiano]

The vinyl on my visors is in great shape. The problem is the foam inside turned to dust. I blew it all out and now they are just vinyl over the metal frame. I have a plan to build a reverse mold and refill them with 4 pound high density foam. It’s a two part liquid really made for the boating industry. I purchased decent originals off eBay to experiment with. What I need is someone with good originals to measure how thick they are and send me some pictures of the edges so I know what they should look like. Thanks in advance for your responses.

[jdamiano]

So it’s 15mm and yes you can refill them. I used Foam-IT 5. It’s a flowing casting foam.
I blew out all the old foam
I cut plywood out leaving access to the holes the mounts go in.
I cut some 15mm spacers
For the passenger with the mirror I cut a piece of cardboard the size of the mirror and a second the size of the mirror surround. Then taped them on.This provides a spacer so they stay recessed.
I sandwiched the visor between the plywood with the spacers using clamps to hold it together.
Now things get real. Had help from my wife. Gotta be quick.
Mixed up 6 ounces of the foam. 15 second stir.
Poured into a disposable pastry bag with a 230 fill tip.
Squirted 3 ounces in each mounting hole and stuck a mount rod in to keep the hole closed and clear. Needed to twist with a wrench to remove after the foam set.
Only have a minute to get the foam in there and spread it around by rotating the thing around.
Careful about covering anything with tape it will cause lines in your visor. Try and clean any spill over quickly.
It came out like a vinyl covered board.
This foam is designed for stuff like this so I’m optimistic it will hold up.