I'm replacing a couple of the more tatty ali panels on the car and slightly concerned about the rivet size used by the builder.

The spacing is pretty much normal, but is a 5mm drill hole not a bit excessive? What are these big holes doing to the strength of the chassis rails?

I used 4mm sealed end rivets for everything....

Sure I used a 3.2mm drill for my 3mm rivets ifs that of help, I used them all over without any probs 3 years down the line.

Cheers

Rich

Ø4.0mm closed end rivets all over including the floor (Ø4.2mm drill).

Thanks guys... would appear that my chassis has lost a fair bit more of its metal than it need have done!

Worth welding up the holes and re-panelling, or just bung more 5mm rivets in and be done with it!??

Mine all done with 5mm rivets and hasnt fallen in half............yet

Welding up the holes won't do any favours for chassis strength - I would just use 5mm rivets and leave it at that.

p.s. I used them in my floor panels - 3mm everywhere else.

Hurrah... my glass is now half-full

Cheers folks!

I used 4mm rivets on the panels I have done so far.

I have often thought of this hole malarky, surely if the hole is being filled with a rivet or the likes, the full strength of the tube will remain ( More or less ) !!??

Of course this assumes the said tube is never going to have a sustantial force applied to the opposite side of the tube

Certainly I wouldn't entertain welding the hole up Scott - IMO you'd do more harm than good and give yourself issues when re-drilling for the next set of rivets.

Repanel with Ø5mm rivets and leave at that.

Cheers Nick!

Thanks for the advice all... 5mm rivets are going back in!

The Hi-cost solution is to use structural locked stem rivets. 6/32" would probably fill the holes. Are you really worried? If so I may have some of these in the depths of my shed - special tools to fit even deeper....

Oooh... interesting development!

Hi

You sure they are 5mm rivets. The kit was suplied with Tucker 4mm sealed rivets. ?
Of course theres no saying the original cutomer used them

Cheers Matt