What is the length of the rivets to be used for a sheet metal repair with two pieces of 0.040-inch aluminum?

To determine the appropriate length of the rivets for a sheet metal repair involving two pieces of 0.040-inch aluminum, it's essential to consider both the thickness of the materials being joined and the requirements for a secure rivet connection.

In this scenario, each piece of aluminum is 0.040 inches thick. When utilizing rivets for such applications, a common practice is to select a rivet length that is approximately 1.5 times the thickness of the materials being joined. This ratio ensures that the rivet can adequately grip both pieces and provide sufficient strength without being excessively long or too short.

Calculating the total thickness of the two pieces, we have:

0.040 inches + 0.040 inches = 0.080 inches.

Applying the 1.5 times thickness guideline, we can calculate the appropriate rivet length:

0.080 inches x 1.5 = 0.120 inches.

Converting 0.120 inches to a more common rivet size, it aligns well with 1/8 inch. However, the selection might favor a slightly longer rivet to accommodate the manufacturing tolerances and to ensure a good connection.

Considering the choice provided, the best option aligns with rivet lengths found