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This video shows one way to upholster a traditional car sunvisor.

As we can see the process starts by making a mold in cardboard then cutting the thin vinyl material considering its stretch side. To add softness on top a thin 3 mm thick foam was laid over the cardboard.

Vinyl and foam both were glued down over the inside edge of cardboard material. Thereafter the final sewing process to sew the edges together and have the sunvisors ready.
The video speaks by itself and I hope you find some useful tips in it.

Cesar