I am trying to join 2 pieces of Aluminum angles (6061, 90 degree, 1/16" thick) together using this self-driving screw:
- Extra-Wide Rounded Head Drilling Screws for Metal
- 1/2" length
- From McMaster Carr (Part # 91515A100)
Problem: Since the 1/2" long screw is longer than two 1/16" thick Aluminum angles stack together, the sharp end of the screw will be protruding out and may injure someone.
Ideal Method: Quick, cheap and safe. Need to make thousands of connections in a day. Looks does not matter.
Is there a quick way to make the end less blunt?
Or will you suggest replacing the self-drilling screws with self-tapping screws which have a blunt end?
Background: I am using self drilling screws with a 20V cordless drill because it is quicker using than using rivets, and I need to make thousands of connections in a reasonable time frame. The rivet gun seems like it will tire me out real quick. I also have no experience using rivets.