🔧 Rivet Size Calculator
Find the correct rivet diameter, length, grip range & drill size for any material stack
| Rivet Dia (in) | Rivet Dia (mm) | Grip Range (in) | Drill Size (in) | Drill Size (mm) | Max Shear (lbf) Al | Max Tensile (lbf) Al | Typical Use |
|---|---|---|---|---|---|---|---|
| 3/32" (0.094) | 2.4 mm | 0.02–0.19" | #40 (0.098") | 2.5 mm | 170 | 200 | Light sheet, plastics |
| 1/8" (0.125) | 3.2 mm | 0.06–0.25" | #30 (0.129") | 3.3 mm | 310 | 375 | General fabrication |
| 5/32" (0.156) | 4.0 mm | 0.13–0.38" | #21 (0.159") | 4.0 mm | 500 | 580 | Medium structures |
| 3/16" (0.188) | 4.8 mm | 0.19–0.50" | #11 (0.191") | 4.8 mm | 730 | 830 | Heavy fabrication |
| 1/4" (0.250) | 6.4 mm | 0.25–0.62" | F (0.257") | 6.5 mm | 1290 | 1460 | Structural/trailer |
| 5/16" (0.312) | 7.9 mm | 0.31–0.75" | O (0.316") | 8.0 mm | 2010 | 2280 | Heavy structural |
| Rivet Dia | Hole Clearance | Drill Number | Drill Dia (in) | Drill Dia (mm) | Recommended RPM (Steel) | Recommended RPM (Alum) |
|---|---|---|---|---|---|---|
| 3/32" | +0.004" | #40 | 0.098" | 2.49 mm | 2,500 | 4,800 |
| 1/8" | +0.004" | #30 | 0.129" | 3.28 mm | 1,900 | 3,600 |
| 5/32" | +0.003" | #21 | 0.159" | 4.04 mm | 1,500 | 2,900 |
| 3/16" | +0.003" | #11 | 0.191" | 4.85 mm | 1,250 | 2,400 |
| 1/4" | +0.007" | F | 0.257" | 6.53 mm | 950 | 1,800 |
| 5/16" | +0.004" | O | 0.316" | 8.03 mm | 750 | 1,400 |
| Type | Access | Strength | Install Tool | Common Sizes | Best For | Watertight? |
|---|---|---|---|---|---|---|
| Blind / Pop | One side | Moderate | Rivet gun | 1/8"–3/16" | Sheet metal, panels | Sealed type only |
| Solid Rivet | Both sides | High | Rivet set + hammer | 3/32"–1/4" | Structural, aircraft | Yes |
| Semi-Tubular | One side | Medium | Rivet press | 1/8"–3/16" | Leather, plastics | No |
| Structural Blind | One side | Very High | Hydraulic gun | 3/16"–1/4" | Trailer, marine | Yes |
| Drive Rivet | One side | Low–Med | Hammer | 1/8"–3/16" | Nameplates, trim | No |
| Flush Rivet | Both sides | High | Rivet set + press | 3/32"–5/32" | Aerospace, aero panels | Yes |
| Project | Stack Thickness | Rivet Dia | Rivet Length | Rivet Type | Spacing |
|---|---|---|---|---|---|
| Automotive Body Panel | 0.036–0.060" | 1/8" | 1/2" | Blind Al | 1–1.5" |
| Sheet Metal Duct | 0.030–0.060" | 1/8" | 3/8" | Blind Al | 3" |
| Aluminum Trailer Wall | 0.100–0.125" | 3/16" | 3/4" | Structural Blind | 4–6" |
| Boat Aluminum Hull | 0.125–0.188" | 3/16" | 7/8" | Solid Al | 2–3" |
| Steel HVAC Bracket | 0.060–0.125" | 1/8"–5/32" | 1/2" | Steel Blind | 2" |
| Plywood Panel Join | 0.250–0.375" | 5/32" | 1" | Blind Al | 3–4" |
Choosing the right size for rivets is very important. If one gets it wrong, the joint will fail or even become impossible to install. Usually one describes sizes of rivets by means of two main numbers: diameter and length.
One can express them by means of imperial inches or metric millimeters.
Choosing the Right Rivet Size and Length
The most used way to point the size of rivets is the trade name. For instance, rivet of size 45 have diameter of body in 4/32 inches and length of grip in 5/16 inches. Rivet of size 68 have diameter of body in 6/32 inches and length of grip in 8/16 inches.
The first number in that trade name points the diameter in thirty-seconds of inch.
Rivets one sizes according to the hole, in that they enter. Rivet 3/16 fits hole 3/16. The measure of diameter relates to the shank, not to the pin.
Because most rivets require pre-drilled holes, precise sizing is needed, otherwise the installation simply will not work. The diameter of rivet should be around 0.010 to 0.015 inches smaller than that of the hole. To save money, it is best too choose standard diameter of rivet first, like this one avoids buying custom rivet.
There are many kinds of rivets, also solid rivets, half tube rivets, rivets with shoulder, swivel rivets and belt rivets. Each of them has its own uses for various joining tasks. Also they come in different materials, sizes and surface treatments.
Rivets with bigger diameter spreads the tension on broader area, what gives stronger link. Rivets with small diameter answer well for lighter tasks, where one requires less tension.
Finding the right length is also important. The length of the shank of rivet should match the thickness of the two pieces, that one ties, plus 1.5 times the diameter of the stem of rivet. A simple method is add 1/8 inches to the total thickness of the materials, that one ties.
Basically, the length of rivet should match the thickness of the tied objects. The length of grip, that points the second number in the code of size, shows how well the rivet can handle the thikness of materials.
The smallest diameter of shank should reach around three times the thickness of the thickest sheet, that is tied. Then one chooses the nearest standard size of rivet to that value. Among the commonly used sizes of rivets are 3/32, 1/8, 5/32 and 3/16 inches.
Small solid rivets range from 1/16 to 7/16 inches.
Rivets with dome head sit above the surface of materials. Rivets with big flange protect bigger area for extra safety. The main size affects the look of the final piece and its strength.
During repair works, the usual rule is to use thesame size and main type as the rivets, that already are in the surrounding building.
