" jls" wrote in message ...
Anybody ever done this? Yep, I know how to use a sewing machine, just need
a pattern or two and maybe a little advice. Already have the foil and
mylar to sandwich in the middle as a UV barrier.

jls,
An industrial sewing machine will make the job much easier. I
replaced the carpet areas on the interior panels of our Cardinal and
broke half a dozen needles on my old Ward machine. I also broke
another heavy needle in making the cowl plugs (with Sunbrella canvas).
To handle the next projects of making the cabin cover, tailcone cover,
insulated engine/prop/wing/stabilator covers (for next winter), I am
in the process of purchasing an industrial sewing machine (had
initially plan to get a new Sailrite but decided to go for a much
better used machine like Pfaff/Juki/Singer).
For fitting, I find some quick hand stitching to try out the pieces
before final sewing are well worth the effort.
Our plane came with some homemade sunshield with no finished edges.
Since they look pretty old and tired, I will replace them with
Reflectix. Will try carpet seam tape for the edges first. If it does
not work, will find some soft fabric like satin to make the edging.