Strut bar fabrication using rivets instead of welding?

[Darkness and Light]

I enjoy working with my hands and building things mostly models and minatures. I don't know how to weld but I'm sure I could manage drilling holes and using a pop rivet tool. Would there be any problems constructing strut bars using steel plate, 90 deg angled sections, square tubing, and 3/8" steel rivets? According to data sheets the rivets seem to be rated well beyond the forces they would be subjected to. Anyone see any problems with it?

[marlin29311]

I'm not a huge fan of the idea - you realize that you compromise the integrity of the bar by drilling holes through it right? This just doesn't seem like the best of ideas IMO...

[Darkness and Light]

I guess I can see your point, but since the force on the plates/tubing will be perpendicular to the direction of the hole I don't really see how it will make that much difference. A piece of sheet metal with holes drilled in a line will bend more easily along the line, but won't crumple much easier if pushed from the ends. In any case I would be using 3/8" plate and multiple tubes with multiple mounting points to distribute the load over the surface of the plate.

Quick mspaint diagram, there are some dimensional errors, but this is the basic idea. Right click on the image and click on "View image"

[AZhitman]

Shear strength of a rivet is not very high.

Better to:

1) learn to weld2) design it and have a local HS autoshop weld it for you3) buy one of the awesome ones on the market

(I recommend rotorimp's design, which ties the firewall to the strut towers - I have one).

[Darkness and Light]

A 3/16 stainless steel pop rivet is listed with a shear strength of 1000 lbs and thats not going to hold? Holy crap!

Part of the problem with buying is I live in Hawaii, shipping for anything large or heavy is ridiculous. For example I'm reluctant to buy sway bars because shipping will easily be over $100. Shipping is worse for other parts like body kits or exhausts systems.

[marlin29311]

Unfortuantly, because of the force exerted during impact, you could be looking at forces well over 1000 lbs - the high amount of stress applied to a very small area in a quick manner of time can easily break this threshold. Look at rock climbing ropes - they are rated to carry 6000 lbs, but no one weights that much. A sheer fall can generate tons (literally) of force.

Welding is a much stronger and much more durable means of connection.

[Darkness and Light]

What about structural 3/16" rivets, they have nearly as much shear strength as the strut bolts the strut bar would attach to (assuming grade 8 bolts) and twice as many in-line attachment points to distribute the load.

I'm not trying to be argumentative, right now I'm only asking out of academic interest.

[Crazyirish]

Just take a look at the number of strut bars on the market that are designed using rivets. If it was a viable alternative, someone would be selling them. Don't try and reinvent the wheel.

[Darkness and Light]

Well welding would be quicker and cheaper...if you already know how to weld. Drilling holes and using fasteners would drive up the cost of production but since I'm only looking to make 2 bars it barely matters. People don't successfully reinvent the wheel but there are plenty of people doing development with tires.

On the other hand, my uncle is already going to be doing some welding to replace a panel he cut out on my car because of rust. I'll ask him to weld the bars while he still has the equipment out.

[AZhitman]

However, PROPS for wanting to find another way!

(...and hell, it might have worked... but the consequences of failure could be kinda icky...)