Vehicle sun visor and method of making

A sun visor comprises a first visor core half (15), with an integral flap (16) disposed to the first visor core half by an integral hinge (17), bonded to a second visor core half (18), except for the flap, which remains open. Two pieces of suitable material are joined together to form an envelope (10) in the shape of a visor core assembly (9). The visor core assembly is inserted into the envelope, and the material along an open edge of the envelope (38) is inserted into the core and attached along an interior edge (46) of the flap and along an interior edge (48) of the second visor core half. The flap is attached to the second visor core half by use of a plurality of snap fasteners (26, 27, 28), and the closure is further strengthened by inserting a mounting rod (7) into a plurality of aligned apertures (30) defined by a plurality of resilient interdigital bearings (31, 32) mounted to the second visor core half and the flap. A clean, neat seam results along all edges of the envelope.