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« on: December 12, 2023, 07:12:45 PM »
I did a bunch of my horns a few years back. I carefully ground the waffled part of the rivet off and drove the rivet out. Cleaned everything up and coated with rust inhibitor, similar to Boeshield. I made my own gaskets from the heaviest brown paper handle bag I could find. I put them together with nuts and bolts to test. Alignment of the holes is critical to good tone.
After I was happy with the function, I decided to make the look right. I put the original rivets in the lathe and cut the shoulder back a little, about .050", if I remember correctly. I then took a punch and ground the waffle pattern into the face and replaced the nuts and bolts one at a time using a clamp next to the rivet I was working on.