After cutting, the edges need to be heat welded together for a neat job. I sent mine away to get it done - for me, cutting the visors was never going to be a DIY job.
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Your right there.. If you're not to fussed and can live with it, another option is to cut along the end seam , roll back the fabric very carefully, like a condom, cut the rubber where it needs to be cut, roll the fabric back fold in and run a hand slip stitch along the end of the visor.a sewing machine wont get in close enough.nobody will know except you..not perfect but pretty close..5 min job not really that difficult,,,,sounds a bit painful lol..
in the good old days when I use to retrim cars ,,with moulded rubber visors this is how I use to recover all visors .keep a open end pull the the fabric on like a glove and stitch 1 end..
Ian cut ours and tried to do a need job with the remaining material and did an apauling job :D so we sent ours to the department of interior it did cost us 175bux which was a bit ouch but they have been reshaped, and covered with matching grey leather and stiched...they did a bloody good job!!