[Lynn Eades]

Grant, your info is correct for two flat pieces of steel, however the carrier side armour has a large countersink on the outside. Haerikj, I have done one carrier and am working on a second. I put a round head rivet in from the inside and form the dome on the outside. I have used a mix of 3/8" and 10mm rivets in the side armour. Going vertically (eg. angle iron to track guards and floor) they are 5/16" or 8mm. I have bolted mine every second hole and riveted in between. I use a drill 2 sizes larger than the rivet for the 3/8" or 10mm, (an 11/32" drill) This gives room for the expanded rivet to fit in the hole. It also allows the rivet to hold its heat until you work it Quick as you can)
The 1 1/2 x dia. is still good but you might need to allow a little more and experiment with the results until you are happy.
The dome on the outside is shallow the same as your lower hull. The hardest ones to access are the ones on the gunners side armour next to the steering box armour. I put my steering box armour up into place after doing those two rivets. The next difficult ones are those above the track guards, front and rear. I plan to rivet my new track guards up into place afterwards. This info depends on your available tooling. I have two big rivet guns. Both have 1 1/16" dia pistons. one has a 4" stroke and the other has a 6" stroke. (I have a 12 cu. ft compressor and std hose) The main thing you need is a motivated assistant to be on the "dolly" (bucking bar) When you are ready with the rivet gun call "push" and you go at it.
(it's just that you need a system) A heat scource for your rivets is required. I just use propane and oxy, but a portable forge would be better. I just pick up the hot rivet with a pair of cheap long nose pliers and insert it in the hole (calmly) It is much easier to stop and reheat a rivet than having to cut it out
I'm sure Richie does it differently, but that's a run down on what I do.
I hope that helps.
Edit: there are only a few thou. difference between 3/8" and 10mm. Like wise, 5/16" and 8mm. Use what you can buy. Be prepared to cut down longer rivets, or looked at another way, dont buy them too short.