So you'd need to be super careful with metal as wood is more forgiving. The big difference is that this method uses the nail head on the back side and rounds the other end on the exposed (decorative side). Here's a tutorial on how to hand rivet copper nails into wood. The bucking bar is used behind the material on the end of the rivet to spread it. When you use air tools, the die that goes in the hammer matches the rivet head. Even with the right size, you can still get smiley faces if you tilt the air hammer too much. Too small and it will distort the rivet head. Too large and you get smiley faces surrounding the rivet on the face of the metal you're riveting. The size of the die is important because it has to match the size of the rivet head. I think I got the tools from Aircraft Spruce. I used an air hammer, dies and bucking bar. I have only done a couple of projects with solid copper rivets. The hardest part of solid rivets is not messing up the surface surrounding the rivet head. Lots of text and I'm not sure if any of these ideas are making sense, a sketch would be better but I'm hot on another project at the moment! I think also for a framed/non-guided press you'd do well to build the punch into a bronze guide bushing for location, probably 3-4 diameters long. I think for just a few you could use a c-clamp(s) to hold the actual parts together, it could also be made more sophisticated into a hold-down in the same press tool but apply the holding force with a die-spring set that ultimately displaces under the press load but then releases/springs back for the next cycle. I think you'd do well to use something like a dial indicator to get repeatable travel on the press once the process is dialed in. If you used a tool like a cup on one side to support the machined part and a center-punch on the other it would make for an easy upset on the underside in the soft brass. One side could be machined, ball turning tool or (?) on one end, then basically smash the other end to make the upset. So I would try to mess around with a press, hydraulic would be best. How would you design it? where can I get the right rivets? 645" thickness, how important is it to the absolute correct length rivet? The piece is obviously going to be for decoration only, I figure a piece of. Does any one have a good source for information to learn how to do solid rivets? Where to find the correct solid rivets? Problem is I have never done solid rivets. We are thinking of doing a metal frame, held together with solid brass rivets. I do alot of metal fab, and have a bunch of metal working tools, literally no woodworking tools. My girlfriend (fiance) and I recently got engaged, and planning the wedding she decided she wants to do a "guest book" similar to this designīut instead of the wood, picture frame design, she likes the idea of doing a more industrial design. I lurk alot but never post, but I figure now is a good as time as ever. So, this is probably my first time posting.
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