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Re: Alternatives to Welding?
Threading works fine, provided the tube wall thickness is great enough to get at least 3-4 full threads in. Four threads in 1/8 in. thick aluminum means 32 threads per inch, so a 6-32, 8-32 or 10-32 machine screw should work. Gussets are usually attached with a bunch of fasteners, and all that tapping will not be fun. Installing rivets just requires drilling matching holes in gussets and tubes, then installing the rivets.
Many teams, however, use 1/16 in. wall thickness, in which case you don't have enough metal to do the required threads. At this point, pop rivets work best.
If you need to make a change, parts can easily be disassembled by drilling out the rivets. Takes very little time or effort, and you can reassemble them with more pop rivets.
The teams I have worked with love using rivets. Also, they really save on weight over conventional bolting techniques.
Dr. Bob
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