While I have been recuperating from being burned in the can, I have not had the gumption to go work on a model. I just had enough energy to "think" about it, which is where I sometimes get great ideas or big disasters.
In this case it was a great idea.
Sunday night I went in and started in on this little idea. Had it all planned in my head, just had to do the work. I didn't want to use my mill, too much set up. I also didn't want to use my Dremel drill press, not quite solid enough to accurately drill the hole depths.
BUT!
I have an ANCIENT Dremel with an awesome drill press. The Dremel is ancient and quite worn, but the drill press is super tight and made to last forever (NO PLASTIC) It is all steel or heavy zinc castings. Decided to see if my Dremel would fit in place of the old one. It was a smidge loose, but I was able to deal with that with a single layer of card stock wrapped around my Dremel. Perfect fit, solid! WooHOO!
With this new (ancient) drill press, I was able to set up perfect depthing to drill the holes using feeler gauges. There was a process to get the perfect spheres that I won't go into, but it involved a ball cutter from a jewelers set I bought a while back. Ball cutters from about .010 up to just over 1/8th diameter, and there are a bunch in size order.
Here is what I ended up with.
I heat, squish (quickly) into the mold. The plastic cools almost immediately. Then I just tug and the next molded batch pops out of the aluminum mold. At most if I could do "all" the holes I would get 40 rivets. On average now with practice I can get about 25 or so good rivets per squish and it doesn't take that long.