Star Wars Prop - Base Hacker System - Communication Tower Rivet & Resin Reinforcement

Kitbash Components Reinforcement with Rivets and Resin


Problem to Solve


One problem that came up rapidly is all these kits bashed, up pointing gun like attachments to the transmitter towers were not well bonded and broke  off with the slighted knock and only superglued, easy to catch on and leaver off or knock off with sheer forces.


 A system needed to be incorporated to structurally attach these parts not just glue them.


More importantly the Nerf gun cartidge disk they were to attach too was:


  • Fragile
  • It was a crucial part that would be very had to replace, I only had one spare.
  • Too costly to mould
  • I was reluctant to use screws, plus it would be difficult to get the right size.
  • Also, screws would look awful.


Problem Solving Solution - Pop Rivets


Pop rivets seem to be the solution with small holes drilled through then the rivet inserted  and pulled tight, this seems to work and look good too when the rivets were pre painted.


I first tried this with 4 mm steel rivets for a grip distance or around 16mm then 25mm.


This gave a mechanical structural joint not just stick on but I ran into probelms.


Rivet Gun Problems - Rivet Jams and Strenght Needed


On youtube videos rivet guns seems easy to use, I had an old Wilco Discount shop hand rivet gun so I thought I would get some 4mm x 20 mm pop rivet which I had spray painted but could not get my rivet gun working. I could not pull or pop my rivets so thought I would get a better one so tried the likes of:


  • Screwfix Direct
  • Tool Station
  • B& Q
  • Local Hardware stores
  • Tradepoint


Without luck.


Got the best one I could find locally, a Stanley 6-R77 heavy duty with swivel head model which seemed more solidly  from Machine Mart which seemed to sell more professional kit, built but still no luck cutting the rivets when in place


Problem Solving Solution - Switch to Aluminium Rivets



Went on various forums before learning that the issue may be me using Stainless Steel Rivets so I tried 4mm x 25mm aluminium rivet, they seemed to work. Black Rivets also helps avoiding the need to paint them.



Problem Solving Solution - Future Equipment - Electric


Due to difficulties with the huge amount of strenght needed in hands to use the hand riveters and frequency or jamming, I hope to replace these with electric riveters when I can afford them.