Those are good ideas.
One of the questions is, what is the item, and would it have been "tacked" or was it made with square nails, and the folks who looked at the piece to make a reproduction simply saw the square heads, and assumed they used tacks?
I ask, as another drawback from the use of modern tacks..., is they act as a wedge, like a splitting wedge on a log, and often crack things like the block on an ammo box, when tapped into place. More so on pine than on hardwood, but they will sometimes split hardwood. :shocked2: One of my lads also found out that if the tips protrude into the cartridge space in the ammo box, they snag on the paper cartridge and tear them open when removed for loading. :shake:
What we did for cartridge boxes and for putting a leather cover over a wooden chest, is we took a very small drill bit..., 3/32 I think..., and drilled holes in the wood where the tacks would go. Then we used a bench grinder, and held the tacks with a vice-grip, and removed a little bit of the tip. Then the tacks were used, and since the holes were pre-drilled, BUT the holes were smaller than the diameter of the tack shank, the tacks like square nails, grabbed onto the side of the holes without forcing too much of the wood out of the way, BUT didn't protrude beyond the wood.
The trick is..., getting the right size hole so that the sides of the tack shank hold, but not so small that the tack acts like the wedge I mentioned earlier. :wink: So you'll have to experiment with the tacks and different sized drill bits.
LD