Blind rivets, also known as pop rivets, are a popular and versatile fastening option used in a wide range of applications. Blind rivets can be used to join two materials together when only one side is accessible, making them ideal for projects where one of the materials is not easily accessible. However, in order to ensure a secure and strong joint, it’s important to drill the right size of the hole for the blind rivet.

In this article, we will explore in detail the question of “What size to drill blind rivet holes?” and provide you with all the information you need to make informed decisions when using blind rivets in your projects.

The basic principle behind blind rivets is quite simple: the rivet consists of a cylindrical body with a mandrel running through the center. When the mandrel is pulled, it deforms the body of the rivet, creating a bulge that secures the materials being joined. In order for the blind rivet to work effectively, the hole size must be slightly larger than the diameter of the body of the rivet, but smaller than the diameter of the bulge.

The recommended hole size for a blind rivet is typically between 0.1mm to 0.2mm larger than the diameter of the body of the rivet. For example, if you are using a 3/16-inch blind rivet, the hole size should be between 5.0mm to 5.5mm. If the hole is too small, the mandrel will not be able to pull the body of the rivet tightly against the materials being joined, resulting in a weak joint. If the hole is too large, the rivet may not deform properly, or may even fall out of the hole altogether.

When determining the appropriate hole size, it’s important to take into account the material being joined. For softer materials, such as plastics or thin sheet metal, a smaller hole size may be appropriate to prevent the material from deforming or cracking during installation. Conversely, for harder materials, such as thicker metals or composites, a slightly larger hole size may be necessary to allow for proper deformation of the rivet body.

Another important consideration when using blind rivets is the grip range. The grip range is the thickness of the materials being joined, and it can vary between different types of blind rivets. To determine the correct grip range, measure the thickness of the materials being joined and select a rivet with a grip range that falls within that range.

When drilling the hole for the blind rivet, it’s important to use a sharp drill bit that is appropriate for the material being drilled. A dull or improperly sized drill bit can cause the hole to be too large or uneven, resulting in a weak joint. Additionally, ensure that the drill is held straight and perpendicular to the surface being drilled to prevent the hole from being angled or misaligned.

In conclusion, choosing the correct hole size for a blind rivet is crucial for ensuring a strong and secure joint. The hole size should be slightly larger than the diameter of the body of the rivet, but smaller than the diameter of the bulge. Take into account the material being joined and the grip range of the rivet, and use a sharp and appropriate-sized drill bit held perpendicular to the surface. By following these guidelines, you can achieve optimal results and ensure a successful outcome for your project.