Glad I found this thread (almost a year later), since I'm in the middle of making a gorget using that same pattern. I see now how the flaring contributes to the stiffness. I'm just about ready to punch the holes, but there's one thing I haven't figured out yet.
How do you keep the catch pins in place? ie. How do you keep the rivet from simply falling out? It doesn't look like one of those "pushbutton" catches, with a flat spring strip pushing against the rivet head.
I tried a short steel tube (a cut-off "roll pin", aka "spring pin" or "split pin" -
http://www.engineersedge.com/roll_pin.htm ) on the outside, and peening the end of the shank (cut-down shingle nail) over the end of the tube, so that the plate is sandwiched between the rivet head and the bottom end of the tube. My first experiment on a scrap piece was a partial success, but I ended up with the shank bent over at an angle so it was not a snug fit. Next time I'll try a shorter tube (say, 1/8" long instead of 1/4") and take my time peening.
As I was browsing around the hardware store, I came across a display of pop-rivets, and I thought they would do exactly what I wanted - flat head on the inside, with a post on the outside - but that seemed a bit too modern a solution, if you get my drift.
Is it possible that if the hole is punched as small as possible, that you just bash the end of shank down until the diameter (of the shank) near the plate expands to a larger diameter than the hole? (sort of like a pop rivet) It might work for a while, but I'd think it would eventually loosen up.
What's the secret? I've seen references to a "stepped rivet", but I don't see how that helps. (No pictures) Do stepped rivets not have a head? If no head, then do you punch the hole to fit the skinny end, and then peen the skinny end on the inside of the plate?
One other thing about that pattern - the back half plate has one hole on each side, but the front half has two holes. What are the extra pair of holes for? Is it to allow for two different positions (eg. for two sizes of neck)? If it was meant for a pushbutton style catch, I would expect to see three and two pairs of holes.
"It is a primitive form of thought that things exist or do not exist." - Sir Arthur Eddington