I tried pop riveting the baffles directly, but I did not like the indentations it leaves in the aluminum baffle. I used a method that I saw on Ray Sheffield’s RV. He uses a #4 SS washer on the opposite side of the pop rivet head and holds it in place while setting the rivet. No dent, more strength and a much better installation. The other benefit come when the rubber seals need replacing, the rivets will be easier to remove.
