There I was, minding my own business at the kitchen sink washing the casserole dish when in walks Abner with the sun visor from the TR7 and sits down at the table. "What's we'uns has got here is a Bag-o-Rot that sags down into my vision", he mutters, "Short of starting up a sun visor factory, is there any way this can be fixed?"
Little did I know the solution was in my right hand. This visor is typical of all TR7 visors with the interior space filled by an expanding foam that deteriorates faster than it should. I have often wondered, if other than just being cheap, if there was an economical yet sturdier filler material that could have been used. As Abner has a short temper, we decided to perform a bit of exploratory surgery on the visor. He fetched the vacuum cleaner and a section of newspaper to place under it. We had glued on a small vanity mirror of about 2 1/2" x 6 1/8" mounted in a plastic holder many years ago. We don't recall where it came from, probaly some auto parts store or drug store.
We peeled off the mirror, and with a razor blade, sliced about a 5" horizontal cut and about a 1 1/4" verticle cut on each end of the horizontal cut. This enabled access for the vacuum cleaner to suck out the rotted foam from the interior of the visor. Now came the fun part, what could we use as the new filler.
We pondered things like carpet foam padding, the felt pad from underneath the old typewriter in the office, even the possibility of expanding insulation construction foam. Then I glanced around the kitchen and saw it, the dishwashing sponge. "Abner! You and Caleb go into town to the store and bring back the items on this grocery list and a package of plain dishwashing sponges and some more glue."
While they were gone I finished the dishes in the sink.
What they came back with was a six pack of 1/2" x 2 5/8" x 4 1/2" plain dishwashing sponges. In their dry state they are slightly malleable.
Into the visor cavity we inserted four of the dry sponges and with the fifth, trimmed it to fit the remaining space. The two flaps were folded back down, instant drying glue was applied to the backside of the small vanity mirror and pressed down to seal.
It has been over a week and all has gone well with no problems from delamination. The visor holds it's shape and functions as it should. No more sagging. We have yet to try this on the passenger side visor with it's built in mirror.
Costs? The package of sponges was about $3.98 and a two pack of Super Glue was $1.99. The mirror was paid for long ago tho I suspect less than $10.00 would buy another similar one. And, I have one sponge left over. Time expended, not counting going to the store, less than 15 minutes.
For your enjoyment, here are the photos as the operation progressed.
Mildred Hargis
