Instead of buying a new one, I decided to just fix it myself. I’m always up for trying something new. So, I figured out how to do it and wrote an easy (non-sewing) tutorial. It’s also available in PDF format here as well as in the Tutorial sidebar of my blog.
- Foam visor with elasticized cording
- Creative Hands Foam World Glue (non-toxic)
- Disposable 1-inch foam brush or whatever size you want
- Enough fabric to cover the top of the foam cap (less than a fat quarter)
- Enough lightweight fusible interfacing to back the fabric piece
1. Gently pull the elastic cording on the visor out through the holes and set aside for now.
2. If you’re replacing the fabric on an old foam visor, peel the fabric off but save for using as your pattern template.
3. Pin your old fabric piece (or trace around the new foam visor) to your new fabric. Cut out.
4. Apply lightweight fusible interfacing to the wrong side of your new fabric piece per manufacturer’s instructions and cut out.
5. Paint the top of your foam piece with the glue. I use wax paper under my paper/gluing projects and a disposable foam brush; then I can just roll up the whole mess and throw it away when done.
6. Carefully layer your new fabric piece on top of the foam piece and smooth gently. I also edged the sides with the glue just to make sure it sticks well.
7. I put another piece of wax paper over the top of the glued visor and placed a hardback book on top to keep it flat and smooth while it dries. If the wax paper sticks to your visor, you merely peel it off later once your visor piece is good and dry.
8. When your project piece is completely dry, poke holes into the holes in each corner of the visor from the underside of the new cap brim. I used the original holes on the foam as my guide.
9. Insert one end of your elastic cording into the hole from underneath the brim and then do the same for the other end.