Drilling Out Rivets: The Key To Unlocking Broken Bolts And Fasteners

Rivets, those small yet mighty fasteners, can be a formidable obstacle when you need to dismantle or modify a project. Drilling them out can seem like a daunting task, but with the right tools and techniques, it’s entirely manageable. This comprehensive guide will empower you with the knowledge and steps to effectively drill out rivets.

Safety First

Before embarking on this endeavor, safety should be your top priority. Ensure you have:

• Safety glasses
• Earplugs
• Gloves
• A well-ventilated workspace

Tools You’ll Need

To successfully drill out a rivet, you’ll need:

• Electric drill
• Drill bits (various sizes)
• Center punch
• Hammer
• Safety glasses
• Pliers

Step-by-Step Instructions

1. Identify the Rivet Head

Locate the rivet head, which is typically domed or countersunk.

2. Mark the Center

Using a center punch and hammer, make a small indentation in the center of the rivet head. This will act as a guide for drilling.

3. Choose the Right Drill Bit

Select a drill bit slightly smaller in diameter than the rivet head. This will prevent the bit from slipping off the center.

4. Drill a Pilot Hole

Start by drilling a pilot hole using the smaller drill bit. Drill slowly and apply light pressure.

5. Enlarge the Hole

Once the pilot hole is drilled, switch to a larger drill bit and gradually enlarge the hole until it’s slightly larger than the rivet head.

6. Remove the Head

Using pliers, gently grab the rivet head and twist it off. If it’s stubborn, tap it lightly with a hammer.

7. Drill Out the Shank

Insert the largest drill bit into the hole and drill through the rivet shank. The rivet should now be completely removed.

Tips for Drilling Out Rivets

• Use a sharp drill bit for cleaner holes.
• Apply cutting fluid to the drill bit to reduce friction.
• Clamp the workpiece securely to prevent it from moving.
• Drill at a slow speed to avoid damaging the drill bit or workpiece.
• Wear earplugs to protect your hearing from the noise.

Advanced Techniques

1. Countersinking

If you need to countersink the hole, use a countersink bit to create a tapered recess for the new rivet head.

2. Rivet Removal Tool

For stubborn rivets, consider using a rivet removal tool. This tool has a rotating head that grips the rivet and pulls it out.

Common Mistakes to Avoid

• Drilling too fast or applying too much pressure.
• Using a drill bit that’s too large or too small.
• Not centering the drill bit properly.
• Not wearing safety gear.

Wrapping Up: Rivet Drilling Mastery

Drilling out rivets can be a straightforward process if you follow the steps and precautions outlined above. With practice, you’ll become an expert in removing these fasteners and tackling any project with confidence.

Frequently Discussed Topics

Q: What type of drill bit should I use to drill out a rivet?
A: Use a high-speed steel (HSS) drill bit for most rivets.

Q: How do I know if a drill bit is sharp enough?
A: A sharp drill bit will cut through the metal smoothly without chattering.

Q: Can I use a drill press to drill out a rivet?
A: Yes, a drill press offers more stability and precision than a handheld drill.