You use a rivet tool to join two or more pieces of material together permanently. This process, known as blind rivet installation, involves placing a rivet through aligned holes in the materials and then using the tool to pull the pin, which collapses the rivet body and creates a strong joint.
Rivet tools are essential for many repair and building jobs. They let you fasten things when you can only reach one side of the work piece. This guide will show you exactly how to use different types of rivet tools, from simple hand models to powerful air-driven ones. We will cover everything you need, from choosing the right rivet to keeping your tool in top shape.
Selecting the Right Rivet Tool for Your Job
Not all rivet tools are the same. Choosing the correct one saves time and ensures a strong connection. Your choice depends on the rivet size, how often you work, and the material you are joining.
Types of Rivet Tools
There are three main types of rivet tools available. Each has a specific use case.
Manual Hand Riveter Technique
The manual rivet setter technique uses hand strength. It is the simplest and cheapest tool. It works well for small jobs or occasional use.
- Good for: Small rivets (3/32 inch up to 1/8 inch).
- Pros: Portable, inexpensive, requires no power source.
- Cons: Slow, requires significant hand effort, tiring for large jobs.
Pistol-Grip or Lever-Action Rivet Tools
These are slightly more advanced manual tools. They use a lever action to multiply your hand force, making how to set a rivet easier than a basic plier-style tool.
- Good for: Medium-sized jobs or slightly thicker materials.
- Pros: Better leverage, less hand fatigue than basic models.
- Cons: Still manual, speed is limited by the user.
Pneumatic Rivet Tool Use
For serious or professional work, a pneumatic rivet tool use is the best choice. These tools use compressed air to set rivets quickly and with great force.
- Good for: High volume work, larger rivets (up to 1/4 inch), and tough materials.
- Pros: Very fast, consistent force, minimal user fatigue.
- Cons: Requires an air compressor, higher initial cost.
Choosing the Correct Rivet
Before you even pick up the tool, you need the right rivet. A blind rivet selection guide focuses on three main factors: material thickness, joint strength needed, and environmental exposure.
| Rivet Type | Best For | Key Feature |
|---|---|---|
| Aluminum Body | Light materials, general use | Lightweight, resists rust well. |
| Steel Body | Stronger joints, steel or thick metal | High shear and tensile strength. |
| Stainless Steel | Wet or corrosive environments | Excellent rust resistance. |
| Specialty (e.g., Closed End) | Sealing against water or air | Prevents material from filling the rivet body. |
Hole Size and Rivet Diameter: Always match the rivet’s body diameter to the hole size. A rivet that is too small will fit loosely and create a weak joint. Most rivets are sized by their diameter (e.g., 1/8 inch).
Grip Range: This is vital. The grip range tells you the minimum and maximum thickness of the materials the rivet is designed to hold together. If your combined material thickness is 3/16 inch, you must choose a rivet whose grip range includes 3/16 inch.
Preparation: Setting Up for Success
Good preparation ensures the rivet sets correctly and lasts long. This section covers preparing the materials and getting your tool ready.
Preparing the Materials
The success of rivet gun operation relies on properly prepared materials.
- Drill the Holes: Make sure the holes in your materials line up perfectly. Use a drill bit that matches the exact diameter of the rivet body. If the hole is too big, the rivet won’t grip.
- Clean the Area: Remove any burrs, sharp edges, or debris from the holes and surrounding surfaces. Burrs can interfere with the rivet’s ability to clamp down tightly.
- Assembly: Place the pieces of material together, aligning the holes precisely.
Preparing Your Rivet Tool
Getting your tool ready depends on its type.
For Manual Tools
- Select the Nosepiece: The nosepiece fits onto the front of the tool. It must match the diameter of the rivet you are using. For example, use a 1/8-inch nosepiece for a 1/8-inch rivet.
- Insert the Rivet: Slide the body of the rivet into the nosepiece opening. The mandrel (the center pin that sticks out) should face away from the tool.
For Pneumatic Tools
Pneumatic rivet tool use requires a few extra setup steps involving an air compressor.
- Connect Air Supply: Attach the air hose from your compressor to the tool inlet.
- Set Air Pressure: Check the manufacturer’s recommendation for air pressure (PSI). Most pneumatic rivet tools work best between 80 and 100 PSI. Too low, and the rivet won’t set. Too high, and you might damage the tool or the rivet.
- Install Nosepiece: Install the correct nosepiece based on your rivet size, just as you would with a manual tool.
- Load the Rivet: Insert the rivet into the nosepiece.
Utilizing Rivet Tool Accessories
Certain rivet tool accessories can greatly enhance performance, especially with pneumatic tools.
- Catch Bottles: These attach to the tool to collect the cut-off mandrels, keeping your workspace clean.
- Interchangeable Nosepieces: Having a full set allows quick swaps when changing rivet sizes.
- Air Filters/Lubricators: For pneumatic tools, these keep the internal mechanisms clean and lubricated, extending tool life.
The Riveting Process: Step-by-Step Guide
Now we move to the actual fastening process. Whether you are using a pop rivet gun or a powerful air tool, the core steps remain the same.
Step 1: Positioning the Tool
Place the nosepiece squarely against the material where the rivet head sits. Ensure the rivet body is fully inserted through the aligned holes of all materials being joined. The nosepiece must press firmly against the rivet head.
Step 2: Engaging the Rivet Tool
This is where the action happens. The goal is to pull the mandrel through the rivet body with enough force to deform the tail end.
For Manual Riveters:
- Squeeze the handles together firmly and steadily.
- You will feel resistance as the tool starts pulling the mandrel.
- Keep squeezing until you feel a distinct “snap” or release of tension. This sound means the rivet has fully set.
For Pneumatic Riveters:
- Pull the trigger. The tool will automatically pull the mandrel.
- Most quality pneumatic tools have an automatic shut-off feature. Once the rivet is set, the tool stops pulling, and the mandrel snaps off cleanly.
- Release the trigger.
Step 3: Mandrel Removal
After setting the rivet, the mandrel (the pin that sticks out) needs to be removed.
- If you are using a pop rivet gun or a quality pneumatic tool, the mandrel often breaks off automatically right at the surface of the rivet head.
- If it does not break off flush, use side cutters or pliers to carefully snip the remaining pin close to the rivet head. Do not attempt to pull it out, as this can damage the new joint.
Step 4: Inspection and Quality Check
A successful rivet joint looks like this:
- The rivet head on the accessible side is flush or slightly rounded, showing no gaps between the head and the material.
- The materials are pulled tightly together with no gap between them.
- The tail of the rivet (on the blind side) has flared out to create a tight lock.
This inspection confirms how to set a rivet correctly.
Advanced Techniques and Tool Maintenance
To get the best performance, you need to maintain your tools and know how to handle tricky situations.
Advanced Pneumatic Operation
When performing pneumatic rivet tool use, consistency is key for professional results.
- Setting Stroke Length: Some advanced pneumatic tools allow you to adjust the stroke length. A longer stroke might be needed for longer rivets or thicker materials to ensure full expansion of the blind end. Always refer to the tool manual for specific adjustments.
- Air Flow Consistency: Ensure your air compressor maintains steady pressure. Fluctuations cause rivets to set weakly or inconsistently.
Rivet Tool Maintenance
Proper rivet tool maintenance keeps your tools working reliably for years.
Manual Tool Care:
- Clean: Wipe down the tool after use. Remove any metal dust or debris, especially around the jaws (the part that grips the mandrel).
- Lubricate: Apply a small amount of light machine oil (like 3-in-1 oil) to the pivot points and moving parts every few uses. This keeps the action smooth, which is key for good manual rivet setter technique.
- Replace Jaws: The jaws wear out over time as they grip the mandrels. If the tool starts slipping or failing to pull the mandrel, replace the worn jaws.
Pneumatic Tool Care:
- Lubrication: Pneumatic tools require constant lubrication via an in-line oiler or by adding a few drops of pneumatic tool oil directly into the air inlet before use. This protects internal seals and cylinders.
- Filter Air: Always use a filter/water separator on your air line. Moisture is the number one killer of air tools.
- Storage: Store pneumatic tools in a dry place, disconnected from the air source.
Troubleshooting Common Rivet Tool Issues
Even experienced users run into problems. Knowing how to fix these issues is part of mastering the tool. Here is a guide for troubleshooting rivet tools.
| Problem | Likely Cause | Solution |
|---|---|---|
| Rivet mandrel won’t pull through. | Wrong nosepiece size; low air pressure (pneumatic). | Check nosepiece match; increase PSI or use a manual tool. |
| Mandrel snaps off too early (before setting). | Rivet grip range exceeds material thickness; tool worn out. | Use a rivet with a shorter grip range; replace jaws/tool. |
| Rivet head is loose or gapped. | Insufficient pull force; material holes are too big. | Re-rivet with correct force/tool; if holes are oversized, use a larger rivet. |
| Tool leaks air (Pneumatic only). | Worn internal seals or gaskets. | Disassemble the tool (if skilled) or send it for professional servicing. |
| Mandrel doesn’t break off cleanly. | Jaws are worn or dirty. | Clean the jaws thoroughly; if cleaning fails, replace the jaws. |
Dealing with Weak Pulls (Manual Tools)
If you are using a pop rivet gun and it feels much harder than usual, check your grip. If you can’t squeeze hard enough, you might need a better quality tool or switch to a pneumatic model for heavy-duty blind rivet installation.
Dealing with Air Tool Inconsistencies
If your pneumatic tool pulls unevenly, the issue is almost always air supply related. Check the quick-connect fitting for leaks. Ensure the regulator on your compressor is set correctly. Sometimes, air hoses themselves are too narrow, causing a pressure drop before the air even reaches the tool.
Comparing Riveting to Traditional Fastening Methods
Why choose rivets over screws or welding? The answer lies in accessibility and vibration resistance.
Rivets vs. Screws
Screws require access to both sides: you need a place to seat the screwdriver tip and turn it. Rivets only require access to one side, making them ideal for enclosed structures like ducts or tanks. Furthermore, because rivets are permanently set and deformed, they resist loosening caused by vibration far better than threaded fasteners.
Rivets vs. Welding
Welding creates a very strong, permanent bond, but it requires specialized equipment, high heat, and skill. Heat from welding can warp thin metals. Riveting creates a strong mechanical bond without heat distortion, making it safer and easier for many common materials like aluminum siding or sheet metal repairs.
Summary of Best Practices
Mastering any rivet tool requires attention to detail. Keep these key points in mind for every job:
- Always match the rivet diameter and grip range to your materials.
- Ensure the hole is clean and precisely sized for the rivet body.
- When using a pop rivet gun, apply steady, full force until the rivet snaps.
- For pneumatic rivet tool use, verify air pressure is within the recommended range (usually 80–100 PSI).
- Perform regular rivet tool maintenance, focusing especially on cleaning and lubricating the jaws.
Frequently Asked Questions (FAQ) About Rivet Tools
Q: Can I reuse a set rivet?
No, once a rivet is set, it is permanently deformed. Attempting to remove it usually damages the rivet and potentially the surrounding material. You must drill out the old rivet to remove it.
Q: What is the difference between a rivet and a pop rivet?
A “pop rivet” is a specific type of rivet, also known as a blind rivet. The term “pop rivet” refers to the sound the mandrel makes when it breaks off during the setting process. Most modern riveting discussed here involves blind rivets.
Q: How tight should the connection be after setting a rivet?
The two pieces of material being joined should be clamped tightly together with no visible gap between the material surface and the rivet head. The joint should feel solid and resist pulling apart.
Q: Do I need specialized training for a pneumatic rivet tool use?
While basic operation is simple, professional use requires training on air pressure safety and tool longevity. For heavy industrial applications, certification might be necessary, but for general repair, following the user manual closely is sufficient.
Q: What is the maximum thickness a manual rivet tool can handle?
This varies greatly by tool quality. Generally, good manual rivet guns can handle steel rivets up to about 1/8 inch in diameter in materials totaling around 1/8 inch thick. For anything thicker or harder, a pneumatic model is strongly recommended.