Karl from Make It Kustom demonstrates how to make a dimple die punch tool to countersink flat or oval head screws with a tapered underside into sheet metal.
This tool is great for interior door panels, dash panels, and other panels where a trim screw and washer may be appropriate. However, this tool will essentially press the equivalent of the trim screw washer into the panel itself.
While a handsome solution, this process can also lead to another solution for bead-rolled panels — it can help flatten bead-rolled panels by shrinking the outer ‘frame’ or flange of a panel to relax the tension caused by the bead rolling process.
In this example, Karl is using a #10 flat head screw with a tapered base. Our personal preference for this type of mount is an oval head screw. The die set will of course facilitate the use of either screw head type.
The top and bottom die for this punch are made from a 3/4 inch cold-rolled steel rod. The bottom section is 2 inches in length, and the top section is 4 inches to provide enough area for it to be comfortably held with your hand. The center hole is drilled to 3/16″ to accept a 3/16″ guide pin.
Editor’s Note: This project does require the use of a metal lathe.
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