Rivet Removal Procedure

2018.01.18

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 Rivet Removal Procedure

Removing Rivets
A specific
Text Arial 10pt procedure exists to drill out and remove rivets from structures. This

procedure must be followed so that damage to the existing hole or nearby structure
does not occur.
Step 1: BE PATIENT. Coming at the problem in a rush can lead to carelessness
and creates needless damage. So take your time and do the job right.
Step 2: Use the right tools.
• Use a sharp drill bit
• Correct size drill bit
• Drill block and correctly sized bushing
• Correct size punch
• Tools to support structure behind the rivet to prevent deformation / damage
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If you don’t have the proper tools don’t attempt the job. Failure is guaranteed.

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 Rivet Removal Procedure

Always use a sharp drill bit.

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 Rivet Removal Procedure
Drill the head of the rivet, not the tail.

DO DON’T
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 Rivet Removal Procedure
Why not drill the tail?
The tail of the rivet is not always centered on the hole!
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n ter
l e ce
nt e r Ho
a i l ce
T

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Drilling the tail is almost guaranteed to
damage the underlying skin or structure.
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 Rivet Removal Procedure
Step 3: Centerpunch a dimple into the rivet in preparation for drilling the first
hole. Punch it as close as possible to the center of the rivet head.

Universal Rivet
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 Rivet Removal Procedure

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Mark your
center point

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 Rivet Removal Procedure

How the dimple looks after centerpunching.

Use
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Universal Rivet Countersunk Rivet

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 Rivet Removal Procedure
Step 4: Drill the first hole, using a #40 size bit. Keep the bit centered at
each stage of hole drilling. Do not allow the drill to slide off the rivet
head. This will result in damaged or scrapped parts.
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Universal Rivet

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Stop after the drill first penetrates and check to ensure your hole is centered.

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 Rivet Removal Procedure

Text Arial 10pt Countersunk Rivet

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 Rivet Removal Procedure
Step 5: Continue drilling your hole using a drill block and bushing to keep the
hole centered and perpendicular. Drill your first undersized hole to a depth
approximately half the thickness of the material being held together by the rivet.
Drilling
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10pt the way through the rivet will make it difficult to punch out later. Adjust

drill speed to maintain control.

Universal Rivet

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 Rivet Removal Procedure
Countersunk Rivet
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 Rivet Removal Procedure
Diagram illustrating drilling depth for first hole and
subsequent undersize enlargement holes

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½ Depth

Undersize
hole

½ Depth

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Drill to half the depth of riveted materials

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 Rivet Removal Procedure
Diagram illustrating drilling depth for first hole and
subsequent undersize enlargement holes

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½ Depth

Undersize
hole
½ Depth

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Drill to half the depth of riveted materials

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 Rivet Removal Procedure
Step 6: Enlarge your hole using a drill block and bushing with a larger drill bit.
Step up your hole size gradually, always keeping the hole undersized. Continually
verify that your drilled hole remains centered in the rivet.
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Universal Rivet

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 Rivet Removal Procedure
Countersunk Rivet
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 Rivet Removal Procedure

Correctly centered hole after enlargement

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Universal Rivet Countersunk Rivet

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 Rivet Removal Procedure
Step 7: Your final hole should be the same diameter as the rivet shank, and
drilled no deeper than the depth of the rivet head. No penetration into or
damage of the underlying structure is allowed.
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Universal Head
Final hole for
head removal

Undersized hole
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 Rivet Removal Procedure
Countersunk Head
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Final hole for

head removal

Undersized hole
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 Rivet Removal Procedure
Diagram illustrating drilling depth of
final hole for rivet head removal
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Universal Rivet
Final
hole

Undersize
DO NOT NICK STRUCTURE
hole

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• Drill only to the depth of the head
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 Rivet Removal Procedure
Diagram illustrating drilling depth of
final hole for rivet head removal
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Countersunk Rivet
Final
hole
Undersize DO NOT NICK STRUCTURE
hole

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• Drill only to the depth of the head
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 Rivet Removal Procedure
Step 8: Using a pin punch matching the hole size in the rivet head, insert the
punch into the hole and pry off the head. It should snap off with minimal effort.
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Universal Head

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 Rivet Removal Procedure
Countersunk Head
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 Rivet Removal Procedure
Step 9: Using a pin punch smaller than the rivet diameter, hammer the rivet shank
out of the material. Back up the structure to prevent dents and always use a
partner during this operation.
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If the rivet does not come out easily, drill additional material out of the shank using the
undersize drill bit to relieve pressure on the surrounding material. Remember to use a drill
block and bushing.
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 Rivet Removal Procedure
Final finished hole

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Universal Head Countersunk Head

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After rivet removal, check for burrs, lack of roundness,
or other forms of damage. Deburr if needed.
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 Rivet Removal Procedure
Step 10: Using a Go-No Go gauge, inspect the hole for correct diameter to
ensure that material has not been removed.

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 Rivet Removal Procedure
The green side of the gauge should fit in the hole
The red side of the gauge should not enter the hole.

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 Rivet Removal Procedure

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DO’S & DON’T’S

of
RIVET REMOVAL
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 Rivet Removal Procedure

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Maintain drill control

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 Rivet Removal Procedure

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DON’T

Allow your drill to slip off the rivet

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and run across the surface

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 Rivet Removal Procedure

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DO

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Keep holes centered

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 Rivet Removal Procedure

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DON’T

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Drill holes off-center

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 Rivet Removal Procedure

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DON’T

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Damage underlying structure
by drilling holes off-center
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 Rivet Removal Procedure

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DO

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Drill your final hole no deeper

than the depth of the rivet head
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 Rivet Removal Procedure

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DON’T

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Drill clean through the rivet

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 Rivet Removal Procedure

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DO

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Drill your holes perpendicular
to the surface

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 Rivet Removal Procedure

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DON’T

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Drill holes off-angle

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