Drilling Out Rivets

You will need to drill out a lot of rivets, so getting good at it will be important. Consider using some scrap material, riveting it, and drilling them back out, just for the practice. If you end up with any pieces (e.g. if you ruin something), consider drilling out all of those rivets for practice as well.

Here is a short video demonstration on drilling out a rivet: https://www.youtube.com/watch?v=kZtPplHomHw

Here is a longer video demonstration: https://www.youtube.com/watch?v=YNAIwiTE3Ag

How to drill out a flush rivet:

• Use a slightly smaller drill bit than the rivet hole -- for an AD3 rivet, you can use a #42 drill bit. For an AD4 rivet, you can use a #32 drill bit.
• Carefully and slowly drill a hole in the center of the flat head (the factory head) of the rivet. There is already a very small dimple in the center you can use to help, or you can use a center punch to make a larger hole first.
• This hole needs to be straight and centered -- that's the part you need to practice. If you go slow you can "walk" the drill bit around to keep it centered.
• You do NOT want to drill all the way through. You only want to drill down enough to do the next step.
• Use a 3/32 (or 1/8) Pin Punch. Insert into the hole and apply sideways force. If the hole is centered and deep enough, the head of the rivet will pop off. If the pin punch slips out, the hole needs to be drilled a bit deeper.
• Once the head of the rivet is removed, use the same drill bit to drill through the rest of the rivet. The tail should pop out even before you drill all the way through.

How to drill out a non-flush rivet:

• Exactly the same technique works, but it will be tougher to stay centered and straight trying to drill through the round head of the rivet. Practice first on flush rivets.
• Some people find that a removal tool makes non-flush rivets easier, but not everybody prefers this option.