Stiffening Darts

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I was asked to add four darts to this grab handle bracket in order to stiffen it. This to reduce assembly time as the bracket is deflecting when clips are pushed into it. I’m not sure this addition will help but that’s not my problem.

The darts are made with a hammer and special made punch. The die has replaceable inserts so the size of the darts can be changed without making an entire tool.

The top plate was made from fiberglass reinforced polyester body filler. The filler was applied to the waxed surface of the bracket and allowed to harden.

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This is the tool set up for use. There are two different size darts so two punches are shown in place.

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Darts installed. No word yet on the effectiveness.