locogringo, I disagree with those who say don't use rivets. There are very few things in life that I'm certain about but this is one of them. You CAN form heads on frame rivets without any special tools. I know because I did it on my '36 Chevy pickup. I didn't invent this method, I was taught by old timers who actually had used it in construction.
The trick is to "buck" (back up) the rivet with a heavy piece of metal ("bucking" bar) with a drilled or end milled dimple to fit over the end of the rivet with a head on it. Then, patiently tap around the end of the rivet you are forming the head on. Slamming it hard with a heavy hammer splits the metal. Tapping gently around and around forms a nice head with a stock looking appearance.
The advantage of rivets over bolts in a vehicle frame is that forming the rivet head also causes the shank of the rivet to swell to fill the holes completely. That is why they are a very snug fit and have to be driven out to be removed.
Again, I know because I did it when I restored my '36 in the early 70's. If you'd like to see pictures, email me at
[email protected].
