Unusual Uses for Pop Rivets

Pop rivets are handy little items to have around, but you can do more with them than join two pieces of sheet metal together, They are also great for making cable ends and also make great pivot bushes or axle bushes.

Step 1: Grab Your Rivets

This is pretty easy just grab some pop rivets of various sizes and knock the core out with a hammer and a vice. They come out easily and you will have a handy little tube and to use on your next project.

Step 2: Cable Ends and Loops

Bike cables can be a pain if you have to cut the end off but with a small pop rivet tube, you can put an end on it so it says in one piece and doesn't stab you in the finger. Just cut off the swage on the end and insert it into your pop rivet tube and give it a tap with a hammer on the back of the vice.

If you can't hit it with a hammer electrical terminal crimpers work almost as well

Also great for motorbike carburettors if you have to make a new cable, the little end fits perfectly in the carburettor slide.

If you need to make a loop just use a bigger rivet. Great if you want to make fishing lures or snares, also great for emergency repairs or throttle cables on cars and go-karts.

You might wonder how strong is that loop? Very strong!

Step 3: Pivots Bushes and Axles

Pop rivets can also be quite useful if you need a nice pivot. the core can be used for an axle but needs to have the crimped part filed down so it will spin nicely when put onto the tube back to front.

In the example wood has a couple of holes predrilled and the tube and core are tapped in with a hammer. you could also use a nail the correct size if you wanted to.

Step 4: Wheels and Axles

If you make toys or need a small wheel or pulley the rivet can also be useful as the centre and axle for your project, Just file or sand the crip of the core of the pop rivet and you have the perfect little axle and centre for your next wheeled project.

I've also used rivets to repair the small pulled inside some car door window regulators, as sometimes the plastic pulleys fall to pieces if they are not too far gone you can replace the centre with a rivet.

Comments

[tytower]

Good stuff
On your wire loops I would like to see the tail extended enough to get a second smaller crimped ferrule on there.
I've overlooked the possibility of using them to crimp on the ends of electrical cables too.

[privatier]

The usual way to hold the strands of electrical wires together is with so called ferrules, which, like the wires themselves, come in different sizes.They are thin enough to fit into the small holes in the plugs and allow for the screw to press the strands together for a strong mechanical connection. I am not sure whether the rivet sleeves are a good substitute.

[tytower]

Hmm yeas you seem unsure of yourself . The best cure for that is do it. You will be surprised.

[ElectroFrank]

Not suitable for electrical use. Aluminium has a surface coating of insulating oxide. That is why it is almost never used in electrical applications.

Also, for vehicle or outdoor uses, coat the cable in grease before putting the crimp on, to prevent electrochemical corrosion due to water ingress.

[tytower]

Well all the power lines are alloy these days . Don't know why you think it is an insulating layer. In fact it is aluminium oxide and that is not an insulator . Its effectively rust on alloy and treated the same is very effective in connections . Ie the latest Lithium batteries LiFePo4 or LFP batteries have alloy terminals . Its always advisable to clean the connections on steel ,copper ,alloy etc and apply a conductive grease immediately . They all rust left dry.

[shloime]

for my purposes, it’s easier to trim the loose end flush (or as close as possible) to the ferrule, using a dremel and a cutoff wheel. (and always use eye protection!)

[liquidhandwash]

Thanks, Tytower, I'm sure I've forgotten another use for pop rivets, Im sure Ive used them for something else.

[Yonatan24]

I like the cable ends idea. I'll try it next time. Thanks!

[mikethevol]

Great article!
Does anyone make copper pop rivets? I have often wondered about using them to breadboard circuits.

[shloime]

neat stuff! it never occurred to me that i didn’t need to buy those aluminum ferrules at the hardware store. 😉

one trick i picked up the last time i made a cable was that it's neater to cut aircraft cable with a dremel cutoff wheel than with wire cutters or anything else i’ve tried. and it doesn’t leave at those loose wire bits sticking out. it just requires a (very) light touch.

[throbscottle]

Thanks for some great tips!
When I can figure out how to vote, I will!

[f1dd13r]

Great ideas. I especially like the bicycle cable ends and will likely use that one and the loop ends idea

[farmboy79]

Thankyou for sharing this! Another great example of creatively looking at things as raw materials suitable for different uses than originally intended.

[liquidhandwash]

Thanks, for your kind words

[qorlis]

On your wire loops, if you don't use a hammer or crimping pliers, you could also use the vise itself.

[liquidhandwash]

thanks for the tip!

[chefspenser]

Thank you for sharing these ideas - creative thinking!

[liquidhandwash]

thanks for the feedback

[snorlaxprime]

That is a great use for a pop rivets, thanks for sharing. This will definitely benefit lots of people.

[liquidhandwash]

thanks for the feedback