View Single Post
Old 12-04-2010, 12:19 PM   #4 (permalink)
bobski
EcoModding Apprentice
 
Join Date: Jan 2010
Location: Newark, DE
Posts: 143

'91 CRX - '91 Honda CRX DX
90 day: 34.91 mpg (US)
Thanks: 0
Thanked 14 Times in 14 Posts
Pop rivets perhaps?
I would get some wide washers to spread out the load (aluminum preferably since the body of most pop rivets is aluminum, but stainless steel would also provide corrosion resistance), with the center hole matched to the rivet. Then just go washer, CP panel A, CP panel B, washer, with a rivet through all of them. Putting a little RTV sealant (just purpose-specific silicone caulk) on the face of the washer that meets the panel, and even between the panels could help minimize the possibility of tear-out due to vibration or other strain. It won't bond to the CP panels, but would provide some traction so the components don't slide past each other so easily.
If you want to do a butt joint, pick up a small roll of aluminum flashing (check the siding/roofing area of your local home improvement megamart), cut a strip a couple inches wide to span the joint and provide some grip area (overlap between the panels and strip) for the rivets. Cut a similar panel for the back side of the joint so you get the same metal-panel-metal sandwich the washers provided. Ever so slightly rolling the edge of the metal strips so they press against the CP panels when installed should keep things smooth airflow-wise, though the rivet heads would still stick out a little.
  Reply With Quote