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©2015 Barry Smith - Fragments of pure copper nails - after cutting down for riveting - will go into the smelting container. |
Over the last 5 days I have been working on metal covers for books. Rivets are a design feature of the covers. In all I have made 16 sets of covers which entailed hand setting 410 copper rivets.
My copper rivets start life as small (1.5mm in diameter and about 20mm long) pure copper nails I purchased in Japan. As part of the riveting process these nails are: set, cut to size, domed and hammered flush with the surface.
Following are some photos of the process and the final products in the rough.
The tools
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©2015 Barry Smith - Tools - left to right - riveting hammer, centre punch, depth gauge, flush cutters, home made setting tool, homemade doming tool, copper hammer (for use on punch, string and doming tools) and anvil. |
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©2015 Barry Smith - Face of doming tool after 410 rivets |
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©2015 Barry Smith - Face of setting tool after 410 rivets |
Setting the rivets
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©2015 Barry Smith - Setting tool in action - formerly a bolt. |
Cutting rivets to size
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©2015 Barry Smith - 1mm thick aluminium used to measure rivet - cut off with flush cutters. |
Doming the rivets
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©2015 Barry Smith - Doming tool in action |
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©2015 Barry Smith - Domed rivet |
A trick I learnt - holding the pieces of metal together with double sided tape; and using the clamp to make sure of a really good connection. Then there is no need for clamps etc when centre punching, drill ing and riveting.
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©2015 Barry Smith - Double sided tape |
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©2015 Barry Smith - Clamp to ensure connection with tape. |
Casualties - I used about 25 1.5mm metal bits in drilling the holes for the rivets. The stainless steel was very hard and either busted the bits (after as little as 3 holes) or wore them out (maximum out of a bit was 24 holes). I used a drill press for the job to keep the revs down and the pressure gentle and even.
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©2015 Barry Smith - Drill press |
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©2015 Barry Smith - Some of the busted and worn out drill bits |
Riveted front and back pages ready for grinding, polishing and then etching.
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©2015 Barry Smith - Riveted stainless steel |
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©2015 Barry Smith - Riveted stainless steel |
I achieved my goal of getting the riveting done by FRiday. Now that deserves a glass of red.