Rivet Size Calculator
Find the correct pop or blind rivet size for your joining project. This calculator recommends the rivet diameter, grip range, minimum length, and corresponding drill bit size based on your material thickness and type.
Thickness of the material on the rivet head side
Thickness of the material on the mandrel side
How do I determine the correct rivet diameter?
A common rule of thumb is that the rivet diameter should be approximately 3 times the thickness of the thickest material being joined. For example, joining 0.064in aluminum to 0.064in steel: thickest = 0.064in, rivet diameter ≈ 3 × 0.064 = 0.192in. The closest standard rivet diameter is 3/16in (0.1875in). For structural joints, use engineering specifications rather than rule of thumb.
What is the proper rivet grip range?
The grip range is the total thickness of all materials being joined. The rivet should be selected so that the total material thickness falls within the manufacturer's specified grip range for that rivet. As a general rule, the rivet length should be at least 1.5 times the rivet diameter longer than the total material thickness to ensure proper mandrel engagement and clinch formation.
How do I choose between blind rivets and solid rivets?
Blind rivets (pop rivets) are installed from one side and are ideal when you can only access one side of the joint. They work well for sheet metal, gutters, and automotive repairs. Solid rivets require access to both sides and are used in structural applications like aircraft and bridges where maximum strength is needed. For most DIY and light industrial applications, blind rivets are the practical choice.
What drill bit size should I use for rivets?
Drill the rivet hole approximately 0.002-0.003in larger than the rivet diameter for standard applications. For 1/8in rivets, use a 1/8in (#30) drill bit. For 5/32in rivets, use a 5/32in (#22) bit. For 3/16in rivets, use a 13/64in (#10 or 11) bit. For 1/4in rivets, use a 17/64in bit. The hole should be tight enough to prevent excessive play but loose enough for easy insertion.