Blinded by the light! Where is that Visor?

This month we took another trip to Disney World. We live nearby and have annual passes so we go often. As usual I forgot to bring a hat and the sun was really getting to me. Of course, Disney has a million hats to sell you at the park, but I prefer a lightweight visor. For our next trip, I am determined to remember to pack a visor and decided one of those foam visors would be the perfect style.

I found a foam visor at my local craft store and realized I could just as easily cut one on my Maxx Air. I scanned the visor into Make The Cut! with the Pixel Trace tool and went to town decorating it. I will make up a few and store them in my car so I don’t forget one next time!

 

Materials

Craft Foam – I used a 3mm craft foam, it required some extra blade to get a good cut.

Vinyl – Gemstone Metallics

Clear Transfer Tape

Coil Cording – This is hard to find, but you can use a coil wrist keychain bracelet or coil shoelaces cut to size. Amazon is a good source for these. Coil-Bracelet-Keychains

Mickey Visors – Download the Disney Visor project file/SVG to make your own.

Since our next trip is around St Patrick’s Day I designed a Mickey and Minnie head filled with shamrocks. I am giving away the design in in the project/SVG download, but I will walk you through my design process.

  • Create your fill pattern by duplicating your image and offsetting the rows. Join all rows.
  • Layer your mouse head over the fill and move it around until you get a pleasing fill inside the shape.
  • Perform a Boolean Join B-A.
  • Create a Shadow Layer of the mouse head. I made mine thin, mitered at .0360.
  • Layer and align the shadow layer and the Boolean join result in step 3.
  • Join the layers.
  • Create a weeding rectangle and join to the mouse head. Now you are ready to cut!

 

 Maxx Air Settings

Gemstone Metallics: Red Blade, Force = 42, Speed = 250, Passes = 1, Blade Height = 25

Craft Foam 3mm: Blue Blade extended to the depth of the foam, Force = 80, Speed = 200, Passes = 2, Blade Height= just barely above the surface of the foam (start with 25 in testing) Note that the project file has a Punch Hole layer. This is included as a reference only; these holes are too small to cut in craft foam. Hide this layer before cutting the foam.

To assemble:

  • Apply the vinyl to the visor using the Clear Transfer Tape.
  • Glue the cord support circles to the outside of the visor tips.
  • Punch holes through the tips with an awl.
  • Thread the coil cording through the holes.

Make several with different decorations and embellishments for a fun way to keep your eyes shaded from the blinding sun!