How To Drill Out Rivets

Drilling out rivets is a relatively simple process, but it requires the right tools and techniques to ensure a successful outcome. Whether you’re removing a rivet from a piece of furniture, a vehicle, or any other application, following these steps will help you get the job done quickly and efficiently.

First, you’ll need to gather the necessary tools. You’ll need a drill, a drill bit that is slightly smaller than the diameter of the rivet, and a center punch. You may also want to use a pair of safety glasses to protect your eyes from flying debris. Once you have your tools, you can begin the process of drilling out the rivet.

To start, use the center punch to create a small indentation in the center of the rivet head. This will help to keep the drill bit from wandering when you start drilling. Next, insert the drill bit into the drill and align it with the indentation. Start drilling slowly and gradually increase the speed as you drill through the rivet. Once the drill bit has passed through the rivet, you can stop drilling and remove the rivet head. Finally, use a pair of pliers to remove the remaining rivet shaft from the hole.

Selecting the Right Drill Bit

Drilling out rivets is a straightforward yet crucial task that requires the proper tools and techniques. The selection of the right drill bit is essential to ensure the job is done accurately and efficiently. Here are some crucial factors to consider when choosing a drill bit for removing rivets:

Drill Bit Material: High-quality drill bits made from high-speed steel (HSS) or cobalt are recommended. HSS bits provide a good balance of hardness, toughness, and wear resistance, while cobalt bits offer superior strength and durability for heavy-duty applications.

Drill Bit Diameter: The diameter of the drill bit should be slightly larger than the diameter of the rivet shank. Typically, a drill bit that is 1/64 inch to 1/32 inch larger than the rivet shank will suffice. This ensures that the bit effectively engages the rivet without damaging the material surrounding it.

Drill Bit Type: There are various types of drill bits available, each designed for specific applications. For drilling out rivets, a twist drill bit with a self-centering tip is recommended. The self-centering tip helps prevent the bit from wandering and ensures a precise hole.

Drill Bit Length: The length of the drill bit should be long enough to drill through the rivet completely, including the rivet head and shank. A drill bit that is too short may not be able to reach the base of the rivet, resulting in an incomplete hole.

Sharpness: A sharp drill bit is essential for drilling clean and precise holes. Dull drill bits will struggle to cut through the rivet, leading to increased friction and heat, which can damage the bit and the material being drilled.

Preparing the Rivet for Drilling

Before you start drilling, it is important to prepare the rivet properly to ensure a successful and safe process. Here are the steps involved:

Choose the Correct Drill Bit

Select a drill bit that is slightly larger than the diameter of the rivet’s shank, but smaller than the head. This will allow you to drill around the rivet without damaging the surrounding material.

Secure the Workpiece

Clamp the workpiece securely in place to prevent it from moving while you are drilling. Use a vise or other method to hold the piece firmly.

Center the Drill Bit on the Rivet

Carefully position the drill bit on the center of the rivet’s head. Ensure that the bit is perpendicular to the surface of the workpiece.

Pilot Hole

First, drill a small pilot hole into the center of the rivet head. This will help to guide the larger bit and prevent it from wandering.

Drill Around the Rivet

Using the correctly sized drill bit, drill around the rivet’s shank. Keep the drill bit straight and apply even pressure to avoid damaging the workpiece.

Drill Bit Size	Rivet Shank Diameter
1/8 inch	3/32 inch
3/16 inch	1/4 inch
1/4 inch	5/16 inch

Stabilizing the Drill and Rivet

To effectively drill out rivets, it’s imperative to ensure both the drill and the rivet are securely stabilized. Here’s a detailed guide to achieve this:

1. Clamp the Drill

Secure the drill in a sturdy bench vise or clamp it to a table or workbench. Tighten the clamp or vise sufficiently to prevent the drill from moving during operation.

2. Support the Rivet

If possible, support the rivet head from the opposite side of the workpiece. This can be done by placing a thick block of wood or metal beneath the rivet or using a backing plate.

3. Pilot Hole and Deburring

Before drilling, create a small pilot hole in the center of the rivet head. This will help guide the drill bit and prevent it from wandering. Use a drill bit that is slightly smaller than the rivet head.

Once the pilot hole is drilled, use a deburring tool or a small file to remove any burrs or sharp edges around the hole. This will make it easier to insert the drill bit and reduce the risk of the bit slipping.

The following table summarizes the key steps for stabilizing the drill and rivet:

Step	Action
1	Clamp the drill securely
2	Support the rivet head
3	Drill a pilot hole and deburr the edges

Starting the Drilling Process

Once you have gathered the necessary tools and materials, you can begin the drilling process. Safety should always be your top priority, so wear appropriate protective gear, such as safety glasses, gloves, and earplugs. Ensure that your work area is well-ventilated to avoid inhaling harmful fumes.

To start drilling, position the rivet head directly over the center of the drill bit. Hold the drill perpendicular to the surface of the metal, applying firm, even pressure. Avoid using excessive force, as this can damage the drill bit or the metal. Start drilling at a slow speed, gradually increasing it as the drill bit penetrates the rivet.

Selecting the Correct Drill Bit

Choosing the right drill bit is crucial for successful rivet removal. The bit should be slightly smaller in diameter than the head of the rivet. This will allow the drill bit to cut around the rivet head without damaging the surrounding metal. You may need to experiment with different drill bit sizes to find the best fit for your particular rivets.

Here are some additional tips for selecting the correct drill bit:

Material of the Rivet	Recommended Drill Bit Type
Aluminum or Soft Steel	High-Speed Steel (HSS) or Cobalt Drill Bit
Hardened Steel	Carbide-Tipped Drill Bit
Stainless Steel	Cobalt or Titanium Nitride-Coated Drill Bit

Also, consider the length of the drill bit. The bit should be long enough to penetrate the entire thickness of the rivet, but not so long that it extends beyond the other side of the metal.

Maintaining a Steady Pressure

When drilling out rivets, it is crucial to maintain a steady and consistent pressure on the drill bit. This helps prevent the bit from wandering or breaking, and ensures a clean and precise hole. Here are some tips for maintaining a steady pressure:

Use a Drill Press

If possible, use a drill press instead of a handheld drill. A drill press provides a stable and controlled environment, making it easier to apply even pressure.

Clamp the Workpiece

Secure the workpiece firmly in a vise or clamp to prevent it from moving during drilling. This will help stabilize the drill bit and ensure a steady pressure.

Use a Center Punch

Before drilling, use a center punch to create a small indentation in the center of the rivet head. This will help guide the drill bit and prevent it from slipping.

Apply Pressure Gradually

Begin drilling slowly and gradually increase the pressure as the bit penetrates the rivet head. Avoid applying excessive force, as this can cause the bit to break or the workpiece to move.

Keep the Bit Perpendicular

Hold the drill bit perpendicular to the surface of the workpiece. This ensures that the hole is drilled straight and prevents the bit from bending or breaking.

Avoiding Damage to Surrounding Materials

1. Use a Pilot Punch

Before drilling, consider using a pilot punch to create a small indent in the center of the rivet. This will help prevent the drill bit from slipping off and damaging the surrounding material.

2. Clamp Down the Workpiece

Secure the workpiece firmly in a vise or with clamps to prevent it from moving while you drill. This will reduce the risk of accidental slips and damage to the workpiece.

3. Use a Sharp Drill Bit

A sharp drill bit will cut cleanly and reduce the risk of tearing or damaging the surrounding material.

4. Drill Slowly and Carefully

Avoid drilling too quickly, as this can generate excessive heat and damage the surrounding material. Drill slowly and carefully, using a light touch.

5. Lubricate the Drill Bit

Applying a lubricant to the drill bit can help reduce friction and prevent the bit from binding or damaging the surrounding material.

6. Use a Countersink

Once the rivet head has been drilled out, use a countersink to smooth the edge of the hole and prevent any sharp edges from catching on the surrounding material. To ensure a seamless finish, follow these steps:

Step
Choose the correct countersink size. It should be slightly larger than the diameter of the hole.
Center the countersink on the hole.
Slowly and carefully countersink the hole, applying light pressure.

Using a Pilot Hole Drill Bit

Using a drill bit the same size as the rivet head will often cause the bit to wander and create a hole that is too large. For best results, begin by creating a pilot hole in the center of the rivet head using a drill bit with a diameter of about half the size of the rivet head.

Secure your material to a solid surface using a vise or clamps. Use a center punch to mark the location of the rivet you want to remove. Wear safety glasses to protect your eyes from flying metal chips.

Drilling the Pilot Hole

Select a drill bit with a diameter of about half the size of the rivet head. Use a drill press or hand drill to create a pilot hole in the center of the rivet head. Ensure that the drill bit is sharp and lubricated to prevent it from dulling or binding during drilling.

Enlarging the Pilot Hole

Once you have created a pilot hole, gradually increase the size of the hole using larger drill bits. Select drill bits that are progressively larger in diameter until you reach the size of the rivet head. Use a steady, even pressure while drilling to prevent the drill bit from slipping or wandering.

Removing the Rivet

When the hole in the rivet head is large enough, use a hammer and punch to drive out the rivet shank from the back side of the material. Use a punch that is slightly smaller than the diameter of the rivet shank to avoid damaging the hole.

Removing the Drilled Rivet

8. Remove the Drilled Rivet

Once you have successfully drilled out the head of the rivet, it’s time to remove it. Here’s a step-by-step guide to do it effectively:

Use a Punch or Chisel: Place a punch or a chisel on the remaining base of the rivet and tap it gently with a hammer. This will help break the metal and loosen the rivet.
Pull the Rivet: Once the base is loosened, use pliers to grab the rivet head and pull it straight out. Apply firm pressure to ensure complete removal.
Cut the Rivet: If you’re unable to pull the rivet out, you can use a rotary tool or a hacksaw to cut it flush with the surface. Be careful not to damage the surrounding material.

Additional Tips:

Wear eye protection while drilling and removing rivets.
Use a center punch to mark the exact location for drilling.
Start with a smaller drill bit and gradually increase the size to avoid damaging the rivet or surrounding material.
Lubricate the drill bit with cutting oil or a similar substance to improve drilling performance and extend the bit’s life.

Cleaning the Drilled Hole

Once the rivet has been successfully drilled out, it is crucial to clean the hole thoroughly to remove any remaining debris or burrs. This ensures a smooth and secure installation of the new rivet or other hardware.

Step 9: Use a Drill Bit and Reamer

Materials:

Drill bit (same diameter as the hole)
Reamer (slightly larger diameter than the hole)

Instructions:

Insert the drill bit into the drill and secure it tightly.
Holding the drill perpendicular to the hole, slowly insert the bit into the opening.
Rotate the drill to remove any remaining material from the sides of the hole.
Remove the drill bit and insert the reamer.
Rotate the reamer to smooth and enlarge the hole slightly, ensuring a snug fit for the new rivet.

Tips:

Use a cutting fluid or lubricant to minimize friction and improve the reaming process.
Rotate the reamer clockwise for right-handed holes and counterclockwise for left-handed holes.
Gently apply pressure while reaming to avoid over-reaming or damaging the hole.

Safety Considerations

1. Wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and earplugs, to protect yourself from flying debris and noise.

2. Secure the workpiece firmly in a vise or clamp to prevent it from moving during drilling.

3. Use a sharp drill bit and drill at a slow speed to avoid overheating or breaking the bit.

4. Lubricate the drill bit with cutting oil or a similar lubricant to reduce friction and heat buildup.

5. Hold the drill steady and maintain a perpendicular angle to the surface of the workpiece to ensure a clean cut.

6. Keep the drill bit cool by dipping it in water or lubricant at regular intervals.

7. Stop drilling once the head of the rivet is removed to avoid damaging the underlying surface.

8. Use caution when drilling out rivets from hollow materials, as breaking through may cause damage.

9. Be aware of the direction of rotation of the drill bit and adjust your grip and body position accordingly.

10. When dealing with multiple rivets, follow a systematic approach:

Step	Description
1.	Mark the center of each rivet head with a punch or center punch.
2.	Drill a pilot hole in the center of the marked rivets, using a drill bit slightly smaller than the rivet shank.
3.	Increase the drill bit size and drill out the remaining material of the rivet head.
4.	Use a punch or chisel to break off the remaining rivet shank from the back of the workpiece.

Rivets are a common type of fastener used in a variety of applications. They are typically made of metal and have a head on one end and a shank on the other. The shank is inserted into a hole in the material being fastened, and the head is then flattened to hold the rivet in place. Rivets can be difficult to remove, but it is possible to do so with the right tools and techniques.

To drill out a rivet, you will need a drill, a drill bit, and a center punch. First, use the center punch to mark the center of the rivet head. Then, use the drill to drill a hole in the center of the rivet head. The hole should be slightly larger than the diameter of the rivet shank. Once the hole is drilled, you can use a drift punch to drive the rivet shank out of the hole. Be careful not to damage the material being fastened when driving out the rivet.