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Picture of Repair broken helmet visor
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As most of you downhillers know, the first part to break on your helmet is the visor. 
In my unprofessional opinion the visor isn't really for protection, it's mainly to keep sun out of your eyes so I felt safe epoxying mine back together. 
WARNING: This will void your warranty and crash replacement policy.
 
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Step 1: Epoxy

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Line up the visor pieces as if it wasn't broken (do this while it is still on the helmet, NOT as shown in the picture). Apply epoxy to the outside first. I recommend plumbers epoxy as it is extremely strong and simple to use. 
Don't worry too much about the roughness, you can sand it after it dries.

Wait the appropriate amount of time according to your specific epoxy label.

Remove the visor from the helmet. 
Then apply epoxy to the inside of the visor.

Step 2: Sand

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Sand the epoxy down. You can sand it as far as you want, because the epoxy on the bottom will reinforce it (Do not sand the inside). 
Use a lower # grit, followed by a higher # grit. 
I chose not to sand it down too much for some reason, didn't really feel like it lol. 

Step 3: Tape it up

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Use painters tape to cover the rest of the visor, unless you just want to paint the whole visor.

Step 4: Painting

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Paint it up!

Step 5: End

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Put it back together and go ride!
spiderham3 years ago
Your results and Instructable look great but...

You might want to keep in mind that repairing, repainting or otherwise altering a helmet could change its characteristics. I assume that the visor breaks so easily in order to allow the main body of the helmet to do its job. A new helmet might be cheaper than the alternative.

For repairing plastics, try PlastFix from Urethane Supply Company:
http://www.urethanesupply.com/plastifixhowto.php
I've used it on my motorcycle fairings with great success. It's super simple to use and with little effort, you can achieve a great finish.
skaterqwertyuiop (author)  spiderham3 years ago
Are you sure you don't work for them? :P
I appreciate your concern, but the majority of the visor is still breakable. That way in another crash, if force is great enough, the visor will still break to allow the helmet to do it's job.