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Thread: countersink wheel arches

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    Spanner Monkey

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    countersink wheel arches

    hello

    i'm probably over thinking (engineering) the fitting of my boreham wheel arches, but here are some ideas/questions i'm thinking about right now

    For now the idea is to rivet the alu wheel arches onto the mk2. I dont want to see the rivets, so with the gartrac arch set i bought the gartrac countersink rivets.

    I guess i will have to make the rivet sit a little deeper so i can put a skim of lead or filler on top.

    I found there are countersink drill bits with a cross-hole single flute that should work best in alu



    There also exists a depth stop like the ones from Cleaveland Aircraft tool



    Experiments so far are not so positive
    When i drill a 4mm hole the rivet fits perfect, but when i countersink it, the whole gets a lot bigger; thats probably because the angle of the countersink is 90° and should be less/more

    I also considered glueing the arches on, but at some point you need to apply even pressure to get a decent bond.

    Some probably say just just a bigger size drill bit and get on with it. Maybe there are other ways of fastening the arches without seeing the bolts/rivets.
    I'm even considering countersink allen bolts now.

    i would love to hear about your experiences and opinions

    thanks

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    Mechanic v8ian's Avatar

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    Re: countersink wheel arches

    Counter sinks are available for many angles ranging between the norm of 60 thru to 120degs and custom ones inbetween, You need to measure the angle of your rivet heads, because somewhere in my mind, csk pop rivets are a shallow angle

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    Re: countersink wheel arches

    i have done some more research

    though i would share some more info

    measured the angle of the gartrac rivet, it should be around 120 degrees



    now to find a countersink bit with the following specs
    - 120 degrees
    - alu cutting
    - zero flute
    - 4mm pilot tip so the tool doesnt wander around

    also will need a countersink cage so i can control the depth

    the search continues :-)
    Last edited by filipvdv; 25-11-2014 at 21:03.

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    Spanner Monkey

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    A standard drill bit has an included angle of 118 degrees so that's what I would use to countersink the holes. Good quality drill bit will tackle this job no problems

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    Re: countersink wheel arches

    yes indeed you are right, i'll do some test with a good quality drill bit

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    Re: countersink wheel arches

    for a test is ordered some 120 degree countersink bits for rivet fitment for my wheel arches
    this worked extremely well



    with very little effort, there is a nice and clean countersink


    happy with the result

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    Very nice, skim of filler over the top, job done

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    Re: countersink wheel arches

    Hi there, just going through this at the moment - could you tell me which countersink you went with in the end, the finish look really good. Thanks.

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    Re: countersink wheel arches

    I did mine with countersunk rivets, used a normal drill bit, but even if the rivet sits slightly proud, you just grind it down and them skim over with filler, as long as its countersunk it doesnt really matter if it sits proud a little as you have to grind off the centre of the rivet anyway when it sanps off as it never flush with the rivet head.

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    Re: countersink wheel arches

    I did mine with countersunk rivets, used a normal drill bit, but even if the rivet sits slightly proud, you just grind it down and them skim over with filler, as long as its countersunk it doesnt really matter if it sits proud a little as you have to grind off the centre of the rivet anyway when it sanps off as it never flush with the rivet head.

    http://www.turbosport.co.uk/showthre...392&highlight=

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    Re: countersink wheel arches

    Always fitted our group 2 kevlar arches to Zakspeed(lookalike) mk2 racecar with countersunk rivets.
    Used a carpentry countesink bit. Just a quick touch over the 4mm hole with a slow speed drill.
    Rivet pre painted arches on car.
    A small modelling brush of arch colour was touched over rivets.
    From 10 foot away they were not visible.
    Ok not a concouse car but a very well built & raced mk2.

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    Re: countersink wheel arches

    Thanks guys, think I’ll get myself a test bit of alloy and do a bit of practice with a few different drill bits. Cheers

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