We’re in the process of making gussets for the A and B pillars of our Saab 99 rally car project. To make the gussets stronger, we actually drilled out a series of 3/4-inch holes and dimpled the surrounding area. These dimples actually make the 16-gauge sheetmetal stronger, while the holes make them lighter. It’s a win-win situation.
You place the die through the hole in the sheetmetal, squeeze it in a press or vice, and you’re left with a dimple. We’ll be doing several on this particular gusset.
The hole saw and dimple die were purchased from Trick Tools.com.
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