I'm trying to attach some tiny hinges to some aluminum flashing. I'm trying to make an accordion shaped windscreen for winter camping, which has to collapse flat. Kind of like this but much larger. This kind of windscreen won't work, I need an accordion style. I found some tiny nuts/bolts, high temperature epoxy, and pop rivets. The nuts aren't quite as flat as I'd like, nor are the pop rivets. And the epoxy is, well, epoxy. It seems like there must be a better way to join these, like some kind of flat rivet. Any recommendation on how to do that? I think my old stand by duct tape wouldn't really work well with the heat.

spot welder?

I would TIG it, but if you don't weld Al, take it to someone who does because it's very easy to just burn right through. You could also make some little rivets but think you would be happier with getting it TIG.

I wouldn't know better than these guys, but soldering came to mind.

Part of the problem is when the holes are already in the hinges.
I would likely make rivets, but sewing them on with fine wire or kevlar thread comes to mind. I wouldn't trust any adhesives to do the job, especially when working with two different mat'ls.
Another option is to forgo the hinges and make interlocking corners.

Maybe the rivets used for leather would work. They are flatter then pop rivets. You can buy them in a kit that has the anvil you pound them together with. I don't think welding would work with the two pieces being different material but brazing or soldering might work.
- Rivet Kit - -

quote Coda1: "Maybe the rivets used for leather would work. They are flatter then pop rivets. You can buy them in a kit that has the anvil you pound them together with. I don't think welding would work with the two pieces being different material but brazing or soldering might work.
- Rivet Kit - - "

Oh that looks great. That might just be the ticket.

Small copper or tinners rivets are readily available at most hardware stores. They squash down nice and flat.

rivets

If you are near Rogers MN I could TIG it for you for free.

Never tried this, but I wonder if 3M fire resistant tape would work?

How about going someplace like Office Depot - somplace that does document binding. See if they have metal, spiral spines. You maybe able to drill a series of holes along the edge and use those spiral binders nstead of hinges. Close it up like a notebook.

Have you thought of doing away with hinges all together and creating slots and tabs to join the pieces together?

Aluminum flashing tape.

I picked up the leatherworking eyelet set at Michaels arts and crafts last night. The important thing there is that it comes with the anvil for the eyelets. The problem with the tubular rivets from the hardware store was finding/buying the anvil. I will post pictures of the eyelets in the sheet metal when I'm done.

I think that the hinges are just not the best solution. I think I'll need to redo it with a different joint fastener, or with some kind of tabs, as suggested.

I'm worried that the tape on the corners would break or melt. But maybe if I re-enforced the part where the tape flexes with some heavy duty foil. The other idea I had was somehow using the stainless mesh cloth that they sell for lint catches on washing machines - that mesh seems to flex but not in a way likely to wear out the mesh very quickly.

I made mine out of an old windshield reflector that folded up. Cut it 8" x 30". On the back , I duck taped 4" straws on the ends , center and 2 other spots for stakes. On the front , I put aluminum flashing tape. Weight is nothing, 8"x 6" x3/4". It works great to block the wind.
Best fishes Mike

I suggest bending the edges to form seams and joints that will work for you. Here is a great website that can show you better then I can explain.
Fabrication of Edges, Joints, Seams

This picture is from the website. Hope that gives you an inspiration.

quote Minnesotian: "
I suggest bending the edges to form seams and joints that will work for you. Here is a great website that can show you better then I can explain.
Fabrication of Edges, Joints, Seams


This picture is from the website. Hope that gives you an inspiration.


"

Interesting site. Thanks.

Did you find a solution?
How about peening?