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I'm looking to buy pop rivets to do some gutter replacements, but the smallest "advertised for gutter work" pack available was a 100pk. I'd probably only need 20 at the most (short span). There weren't any dimensions listed, but common sense says they would only need to be around 1/8" x 1/4". Assuming any substitutes should also be aluminum.

What size would be adequate for joining aluminum gutters?

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It depends on your gutter brand's seam overlap. A narrow riveting area should prompt a small rivet (1/8") because you do not want to drill a large hole (for a thicker rivet) which could weaken the gutter material in the riveted area, causing failure of the gutter material under stress.

The grip range required is determined by combined material thickness.

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I recently used 1/8" (3mm) wide, 1/8" (3mm) grip aluminum rivets for fastening aluminum gutter end caps on. Worked great.

I definitely wouldn't go much wider than 1/8" for fastening gutter end caps because there is only about 1/2" of aluminum to fasten to.

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    Gutter caps crimp on. And still have to be caulked. – BillWeckel Oct 9 '18 at 20:33
  • @BillWeckel I've seen lots of professionals on youtube using special gutter end cap crimpers, but I didn't want to buy a $50 CAD tool that I would use only once. Or did you mean just crimping with regular pliers? – afk Oct 11 '18 at 14:27
  • You can just use pliers too. Hell, I use a downspout crimper, but I've used whatever pliers I've had laying around too. Like i said, the end caps still have to be caulked, which will hold the end cap in place once it dries. – BillWeckel Oct 11 '18 at 14:41
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Why not use self tapping sheet metal screws? You've gotta caulk the inside of the gutter at your seams and end caps anyway...

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