So, I installed a new chain this weekend. Cutting the old endless chain off went well, took about 30 seconds of cutting with a dremel. Installed the new chain and a new front sprocket...still good, except one issue. I found that my chain came with a rivet-style master link rather than clip style. I did my best to mushroom the heads of the rivets but I'm not so sure about my work. I measured the heads and they are .202-.204 around. Does anyone know what the size of the unexpanded rivet is?
Looks like .200 inch
http://www.dansmc.com/diamondchainspecs2.jpg (http://www.dansmc.com/diamondchainspecs2.jpg)
To properly install a riveted master link, you should use a riveting tool to form the shop head.
No other method will ensure that the outer link plate is properly spaced and swaged to the pin. Fatigue failure can result.