Securing roof cap to gutter - soft alloy aviation rivets?

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AussieFJ40

AussieFJ40

10 Year
Joined
Jul 19, 2015
Threads
21
Messages
108
Location
AUS
Hi all

About to do this on my truck and recall reading about folks achieving a nice 'oem look' by using soft alloy aviation rivets, similar to the attached pic.

To take some of the guess work out, can anyone recommend a spec/source that worked really well? Would love to see pics. Also - what tool did you use to compress them?

Many thanks.

RIVETS.webp
 
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There is a mandrel and bucking bar that is used to install those. it is basically a heavy piece of steel that you hold against the head of the riveted has to have an impression of the rivet in it to keep from deforming it. Then most use an air hammer with the proper concave punch installed, to set the rivet.
 
No need for washers. Pick up a box of 5/32"x3/8" aluminum round head rivets at McMaster Carr. Chase all the old holes with a 5/32 drill and enjoy bucking 100 rivets!
 
We are thinking of making up a little screw type 'c clamp' in our machine shop to compress the rivets.

Would this work well, or do solid alum rivets respond better to 'impact' forming?
 
Impact via an air hammer it a rivet squeezer. The secret is a dimple on the tool to fit the 5/32 rivet head and a flat bucking bar to evenly spread the rivet. I use both on aircraft depending on location of rivet. Good luck.
 
I used to build aircraft for aerospace and used a heavy piece of solid rod with a concaved dimple on the end. You use that on the head of the rivet to hold it in place and I have what is basically a pneumatic hand nailer to mushroom the rivet. There are many ways to control the amount of compression if you want a very uniform result but thats not really all that important on a Hardtop so long as they are close.
 
Hey Aussie, buy fresh rivets as some of the alloys tend to harden over time and become harder to get a nice mushroom on the rivet. Your local airport mechanic should be able to hook you up on the rivets and might loan you the tools necessary. In Australia a case of quality beer could get the job done at his shop. I have done a lot of "free" jobs for my friends for a cold ice tea and a BBQ sandwich. Aviation people are that way.
 
Helipilot said:
Hey Aussie, buy fresh rivets as some of the alloys tend to harden over time and become harder to get a nice mushroom on the rivet. Your local airport mechanic should be able to hook you up on the rivets and might loan you the tools necessary. In Australia a case of quality beer could get the job done at his shop. I have done a lot of "free" jobs for my friends for a cold ice tea and a BBQ sandwich. Aviation people are that way.
Click to expand...

I did think about that - our workshop is close to the busiest GA airport in Oz!

Failing that these guys are close too - Blind Rivets Solid Rivets - Ullrich Fasteners Catalogue

Does 6061T6 sound like the spec I want for the roof cap?
 
I believe that will work, I will check my reference manual in the morning and post an answer. If you were closer I would just bring my rivet box over and do it in about a hour.
 
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