How to make Fancy Rivet heads
 
Instructions for the construction of a "rosette" rivet.
 
Make a steel master rosette rivet. A variety of tools and techniques may be employed in this process. I used a standard round head rivet and built up the head by welding and then ground and filed the head to its desired shape. Attention to detail and symmetry will result in a better die.

The bottom die is made from steel bar stock. It must be sufficiently wider than the circumference of the rivet head to allow the die face to be braced over a hole when removing the rivet from the die. Drill the center of the bottom die the diameter desired for the rivet shank and the depth required for the rivet shank length. Drill a smaller diameter hole entirely through the die. This will be used to insert a cylindrical punch to tap out stuck rivets. Grind the die face slightly conical so that the rivet head back will be slightly hollow. This aids in getting a nice rivet fit on round surfaces.

The top die is made from steel bar stock. If you have the ability to grind a depression smaller than the rivet head it is preferable to do so, but not entirely necessary. Place your bottom die in a sturdy vise and insert the master rivet. Heat the top die yellow hot and strike it against the bottom die and master rivet. Repeat the process until the desired depression is achieved. Polishing the top die rivet depression will result in prettier rivets that require less clean up.

Cleaning, shaping, and otherwise finishing the exterior of the dies will make them more of a joy to work with but is not essential to their function. If you have bothered to use a reasonable grade tool steel to make the dies, temper as required.

To use the dies, secure the bottom die in a sturdy vise. Place the rivet blank in the bottom die and heat the head yellow hot. Strike with the top die, repeat heating and striking if necessary. Remove the rivet from the bottom die by tapping with a cylindrical punch through the hole in the bottom of the die. Finish rivet as desired.

God Luck, Tom Justus AKA Master Eldrid Tremayne