Pop Rivet Explained: Finding the Perfect Size & Type

How to Choose The Right Pop Rivet For Your Project

Carmakers use pop rivet fasteners in several locations in your car where it would be difficult to use a nut and bolt. So you’ll find pop rivets to attach the window regulator or power door actuator to the door. If you ever have to replace the regulator or actuator and need to replace the rivet. Figuring out which size you need can be confusing, especially if you’re new to using rivets. I’ve worked with all types of pop rivets in various applications, and in this article, I’ll show you how to find the right pop rivet size and type for your application.

For tips on how to remove a pop rivet, see this article

How to Determine the Right Pop Rivet Size

To choose the right pop rivet sizes, you must consider two main factors: the rivet diameter and the grip range.

1. Rivet Diameter— The diameter of the

Rivet measurements

rivet determines how strong the connection will be. A larger-diameter rivet provides more shear and tensile strength, making it ideal for structural applications. Typically, standard diameters include:

3/32″, 5/32″, 1/8″, 3/16″, and 1/4 inch (6.4mm)

A good rule of thumb is to use a rivet at least three times the thickness of the material you’re fastening. If you’re unsure, buying pop rivet assortments is always a good idea, so you have multiple options on hand.

2. Rivet Length Versus Grip Range— The grip range is the total thickness of the materials the rivet can secure. It is not the same as the rivet’s length because you must allow enough room for the mandrel head to expand and compress the material.

Using a rivet with a grip range too short can lead to a weak connection. Measure the total material thickness and choose a rivet with a grip range that includes that measurement.

Head Types of Pop Rivets

Understanding the different head types of pop rivets is crucial for selecting the right one for your job. Not all rivets are created equal, and using the wrong type can compromise your project’s integrity.

Large Flange Head Pop Rivet—The common head type for automotive use is the large flange head because it spreads the grip over a larger area.
Domed Head Pop Rivet— This type of rivet is often used to secure the window regulator. The thicker domed head is stronger than an ordinary flange head pop rivet
Button Head Pop Rivet— This head type is used where you want an inconspicuous look, and rivet strength isn’t the most important feature. You’ll often find button head rivets used to secure gutter downspouts because they are don’t secure a lot of weight and they don’t distract from the appearance.
Countersunk Head Pop Rivet— This type is rarely used in automotive applications because it requires countersinking the top material so the rivet sits flush. Countersunk blind rivets contribute to a cleaner, more professional appearance.

Rivet head styles

Rivet Materials

Aluminum: Lightweight and corrosion-resistant, ideal for general applications. Aluminum rivets are the easiest to install.
Steel: Stronger than aluminum but prone to rust in humid conditions and requires more effort to install
Stainless Steel: Offers excellent corrosion resistance, making it perfect for outdoor and marine applications.

Choosing the Right Blind Rivet Tool For Home and Automotive Use

A homeowner’s blind rivet tool usually comes with several mandrel adapters, like 3/16″,
5/32″, 1/8″, and 3/32″. However, the rivets used to secure large automotive components are usually 1/4″ diameter. To install those, you’ll need a rivet tool to accommodate a larger mandrel and provide longer arms to gain more leverage.

A typical homeowner’s rivet tool kit costs around $25, while a 1/4″ rivet tool costs around $50.

Blind Rivet Tools

How to Buy Pop Rivet Selections for Your Needs

When you buy pop rivet assortments, make sure to choose a variety pack that includes different diameters and grip ranges. If you’re working on a specialized project, buying the exact pop rivet sizes you need in bulk can save money and reduce waste.

When shopping, check the specifications carefully to ensure the rivets meet your requirements. I always recommend buying from reputable suppliers who provide clear sizing information. If you’re uncertain, consult a rivet size chart or speak with an expert before making a purchase.

©, 2025 Rick Muscoplat