Talk about standing on the shoulders of giants. Thanks to all you guys who've blazed the trail on this repair. I leveraged your efforts and applied a few tweaks. All told this took me around an hour or so. Wish I did this a long time ago. Mechanically I give myself an A (now will even stay right up against the windshield). I give myself a B+ on cosmetics because of some adhesive overrun.
For those of you interested, below is my pictorial step by step.
1) Split seam: Used razor blade, stayed on seam in hopes of getting cleaner re-seal at end
2) Peeling back inner tape:
3)Cut away styrofoam to access to mechanism: Tried to remove as 1 piece so that can be re-installed when done. Started by peeling from one corner and it came up because the adhesive was still tacky.
4) Enlarged access to clamp: Didn't get size quite right 1st time so removed bit more styrofoam
5) Screws: Chose sheet metal screws rather than nut/bolt. Screw allows for easy adjustment while installed in car. #8 x 3/8". I wouldn't go any longer than 3/8. Also, this type of screw makes for easy, screwdriver only adjustment when installed in vehicle
6) 1/8" drill bit for screws
7) Screws Installed: Did not use pre-drilled hole becasue it was too big for screws I had on hand. So ended up with 3 screws instead of two like some folks. Applied white lithium grease into gaps. This holds visor in all positions including fully against windshield.
8) After styrofoam and tape are re-installed: Tape was still sticky from original adhesive and styrofoam fit snugly. Not that it affected the outcome, but I think I would glued the styrofoam in place.
9) Upholstery adhesive: $3 at Lowe's. Specifically for vinyl, fabric & plastic. This stuff is on the runny side so used toothpick to apply to fabric and applied directly from tube on the styrofoam. Downside is long cure time (2 hrs to set and 24 to cure). Spec says it's good to 140F which should handle hot car in middle of summer in my area (>100F all summer).
10) Seam taped back up: Applied tape all along the seam trying to keep it from separating anywhere. Used normal office tape which was handy. It did stick to the cured adhesive in places I overapplied the adhesive and created little bit of cosmetic issue (see next pic)
11) Done: Finished product. Finished product. I peeled the tape off after couple of hours (carefully as adhesive was still moist in places). Went back and reapplied to places where seam was not tight. The white residue on right side is due to excess adhesive I applied. I was able to clean up for most part by scraping and a suede brush. Good thing is that the ugly stuff is nearly invisible from driver's vantage point.