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I measured 6 1/8" also, top to bottom. Measuring from the "stub" =11" to the edge of the light/mirror unit, and the thickness is near an inch throughout the length of the visor...it does get thinner towards the stub, approximately 13/16".
It appears to be a hard plastic material under the vinyl/padding. The piece is plenty rigid yet lightweight. The hardboard or maybe some abs plastic should work.
This is definitely not my area of expertise, but I'm interested in seeing it come together.
Ok. So what I am getting from you guys is that this is nearly the exact same visor as the Lincoln. Light weight, hard plastic. I think ABS plastic would be the best material. Thanks for the input.
Oh no, orders already...lol. Better look into the kind like on a 99 Expedition, that are a 2 in one or the kind that have a slid out length extender....