Typically the thinnest skin that a Nutsert can be applied is 0.32" and also a slight flange protrudes above the surface. Here's the process that I did for Access Panels on my 0.016" thick Control surfaces on the Yukon with ATS2-832 Nurtserts;
1) Fabricate Doubler Split Ring of 0.020" thick 6061T6 with hole pattern
2) Drill skin & doubler bolt hole first to 5/32" dia.
3) Dimple the holes with 5/32" die.
4) Drill holes to 0.25" dia.
5) Insert Nutserts thru skin and doubler and compress with Hi-Torquer tool.
- 0.020" thick doubler Split Ring
- Flush Nutsert
The doubler proves a total thickness of 0.036" and the dimpling makes the Nutsert flush but also provides extra material to squeeze against the Nutsert when it in compressed. I have tested the Nutserts with 8-32 screws to max torque of screw to 15 in-lbs.
If anyone wants to use this technique, experiment on some scrap and test to see if it works for you.
This gives another option beside anchor nuts.
