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If you've been stung by your visor coming apart (and you know who you are if you've experienced this), this may work for you.
Its been a while since I did this, but I figured I would post in case anyone else wanted to go this route. If you or someone you know is mechanically inclined, have a couple of spare hours, you'll spend less than $15. Relevant photos attached
First I detached the visor from its mounting location, loosening the two screws. Then, taking care with the wiring, I disconnected the electrical connector.
There are probably many ways to DIY repair the visor. I went to a big-box hardware store and purchased some 1/16" x 3/4" flat aluminum stock.
Your measurements will vary, but you will need to measure, cut, and sand the edges smooth a length of the aluminum stock that will snugly wrap around the clamped visor in the position roughly shown in the last photo. I kept the visor squeezed back into place using some small clamps. I also put pieces of paper towels between the clamps and the visor surfaces to minimize scratches or other marks.
Bending the aluminum to fit may be a bit of trial and error. But when you get the piece to snuggly slip over the clamped visor, in the proper shape, you can use a suitable epoxy along the edges of the aluminum stock to keep it in place. I smeared a little on the flat aluminum surfaces contacting the visor also. Give a day to set, or whatever the epoxy directions say, before taking the clamps off.
Once that was done, I went to Wal-Mart and found a flat machine-gray paint that very closely matched the visor. I masked off the areas with the holes, the inside of the mirror compartment, and the electrical connector (spray the visor with the mirror flip-door closed). I hung the whole visor assembly by a string and sprayed it. I even sprayed over the silly warning sticker, so the visor has a clean uncluttered appearance. If you want to keep the sticker, mask it off.
Its been about 2 1/2 years, and its as firm as ever, with no cracking. YMMV. I did take it down again recently to repaint over some minor scratches I experienced unrelated to the repair. But mechanically, this was the permanent fix for me.
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Last edited by RotaryJeff; 09-26-2010 at 02:10 PM.