In a sheet metal repair using two pieces of .040 inch aluminum, what will be the length of the rivets if all holes are drilled for 3/32 inch rivets?

In determining the correct length of rivets for a sheet metal repair using two pieces of .040-inch aluminum, the total thickness of the materials must first be calculated. Since there are two pieces of aluminum each measuring .040 inches, the combined thickness is .040 + .040, which equals .080 inches.

When using 3/32-inch rivets, which is equivalent to .09375 inches, the rivet length should accommodate the thickness of the materials being joined, considering also the necessary grip required for the space between the parts and the rivet's head.

To find the appropriate length of the rivet, you generally need a rivet that is slightly longer than the total thickness of the materials to ensure a proper join and sufficient expansion of the rivet. The choice of 1/4 inch rivets corresponds to .250 inches, providing a suitable length that not only accommodates the thickness of the two pieces of aluminum but also allows for proper installation without risk of having the rivet too short.

A rivet length of 5/16 inches or 3/16 inches would be either too long or too short, respectively, while 1/8 inch would be inadequate as it would not provide enough grip for the combined thickness.