I'm making a pair of Kant Twist clamps. I'm not using threaded fasteners to hold the plates together; according to the plans I have, I've made pins and am peening the ends. The trouble is that the slop that I thought would go away hasn't. My pin shoulders wound up about 2-3 thou smaller than the holes, and they're about 102 thou long going into 16 gauge (62 thou) thick arm plates. After a few minutes of peening with a small ball pein hammer I have the pin staying in and not falling out, but the 2-3 thou slop is still there and the extra 40 thou that I thought was needed for peening hasn't reduced that much. So, there's slop in both directions.
I'm wondering if: 1) My hammer is too big?...it's 8 oz and on the scale of the 3/16" pins maybe the end is too flat? B) The extra 40 thou beyond the plate thickness is too much? The plans were calling for 60 thou, though. And iii) I just need to spend much more time hammering?
Any tips for peeing would be appreciated.