Is there a practical method by which I can repair the broken spot welds on my aluminum PowerBook’s case? The welds in question bonded two screw lugs to the laptop shell.
How small can the rivets be? There’s only about an eighth of an inch of clearance on the inside, and the other side of the shell is on the outside of the laptop.
The rivets get pretty small. The link shows a picture of a 1/16" diameter rivet, and they come in a variety of lengths. So your 1/8" clearance should be enough; if you can drill a 1/16" hole through the case and the lug mount without damaging things.