Proud bolt heads.

[chunkolini]

Small problem here.
I am fitting access ports to a sheet metal sculpture. I have used 1.6mm sheet for the body and M6 csk bolts to hold the covers in place. All fits nicely but the heads bolts are too tall and stand proud of the material. Not pretty. Is there an alternative style of bolt that will sit flush.

 

[awemawson]

Can you use a broad centre punch to form a conical recess in the sheet to accept the screw?

 

[chunkolini]

I have countersunk the holes but the sheet is not thick enough to have the whole bolt head sunk into it.

 

[armalites]

Why not use a button head, won't sit flush but will look much nicer than that countersunk one

https://www.screwfix.com/p/easyfix-button-head-socket-screws-stainless-steel-m6-x-16mm-50-pack/1558t

 

[chunkolini]

Problem is the internal frame is 3mm so no room to play with.
May be button head bolts it is.

 

[Woody.v8]

Make a die to make or swage a countersink shape in both sheets without removing any material?
I'm thinking similar to a dimple die.

 

[captain-destructo]

i was once told if you mess it up make a feature of it!

dont know what the sculpture is of but can you not exaggerate the panel / fixings into a feature?

OR

drop the frame it fits onto deeper and add some material onto the inside edge of the panel so you can countersink it properly?

 

[Ton-up]

can you weld a nut on the back of the 3mm ?

 

[chunkolini]

Some good ideas there, but it all built inside the sculpture, I think the button head bolts are the way to do it.
I might have a play with a bolt in the chuck of a drill and grind the edge off it.

 

[awemawson]

You can buy little pressed cups to accept counter sink screws: Screwfix stock them

 

[MattF]

As said, just use a non-countersunk bolt. You have plenty of choice of head types: pan, cheese, domed etc. Or, use cup washers as Awe' suggested.

 

[Ton-up]

You find lots of furniture uses 'flat head' bolts like this:-

 

[chunkolini]

Nice surprise this morning.
I popped one in the chuck of my drill and onto a grinding wheel.
Much better