How To Remove Rivets

Rivets are essential fasteners used in various applications, from household repairs to industrial construction. While they can provide strong, permanent bonds, there may come a time when you need to remove them. This guide will walk you through three effective methods for removing rivets, along with the tools and techniques you’ll need for each approach.

Common Types of Rivets

A rivet is a permanent mechanical fastener used to join two or more pieces of material together. It consists of a smooth cylindrical shaft with a head on one end. When you install one, the tail end is deformed, creating a second head that secures the materials in place. 

These fasteners are durable and strong, making them a common choice in construction and manufacturing. There are several types of rivets, each designed for specific applications:

• Blind rivets (pop rivets): These are the most common type for DIY projects and home repairs. You can install them from one side of the workpiece, making them ideal for areas with limited access.
• Solid rivets: Used in heavy-duty applications, these require access to both sides of the workpiece for installation.
• Semi-tubular rivets: These have a partially hollow shaft and are often used in automotive and furniture manufacturing.
• Drive rivets: These are installed using a hammer and are common in leather and woodworking projects.
• Split rivets: Featuring a split tail, these are useful in soft or brittle materials, allowing for a more secure grip.

Applications of Rivets in Home and Industry

Rivets are used in a wide range of applications, including:

• Joining sections of gutters and downspouts
• Assembling metal furniture
• Constructing aircraft and vehicles
• Fabricating metal structures in construction
• Repairing appliances and electronics
• Securing fabric in tarpaulins and banners

Essential Tools for Rivet Removal

Having the right tools is essential for successful rivet removal. Here are the items you’ll need:

Drill and Drill Bits

A power drill is the primary tool for most rivet removal methods. You’ll need a set of drill bits in various sizes to match different rivet diameters. High-speed steel (HSS) bits are suitable for most applications, but you may need cobalt bits for harder materials. 

Rivet Removal Tools

Specialized rivet removal tools can make the job easier and more precise. These include:

• Rivet extractors: Grip the rivet’s mandrel, allowing you to pull it out cleanly
• Dedicated rivet removal drill bits: Have a guide that centers the bit on the rivet head
• Rivet guns with removal attachments: Some rivet guns come with accessories designed for rivet extraction

Safety Equipment

Always prioritize safety when working with tools and metal. Essential safety gear includes:

• Safety glasses to protect your eyes from metal shavings
• Work gloves to guard against sharp edges
• A dust mask to prevent inhalation of metal particles
• Ear protection if using loud tools like drills or hammers

Method 1: Drilling Out Rivets

Drilling out rivets is the most common and versatile removal method. It’s suitable for most rivet types and materials.

Step-By-Step Guide To Drill Out Rivets

1. Select a drill bit slightly larger than the rivet’s mandrel.
2. Create a starting point on the rivet head using a center punch.
3. Position the drill bit on the center punch mark.
4. Drill slowly through the center of the rivet head.
5. Increase pressure slightly as you drill through the rivet body.
6. Stop drilling when you feel the rivet head separate from the shaft.
7. Remove any remaining pieces of the rivet with pliers or a punch.

Tips for Successful Drilling

• Use a low drill speed to prevent overheating and damaging the surrounding material.
• Apply steady pressure to keep the drill bit centered on the rivet.
• Lubricate the drill bit with cutting oil for smoother drilling and longer bit life.
• Securely clamp the workpiece to avoid movement during drilling.

When To Drill Out Rivets

Drilling is ideal for most rivet-removal situations, especially when dealing with blind rivets or when you don’t have specialized tools. It’s also the best choice when working with delicate materials that could be damaged by more aggressive removal methods. If precision is essential, this method provides control and minimizes damage.

Method 2: Using a Dedicated Rivet-Removal Tool

For those who frequently work with rivets, a dedicated removal tool can save time and provide more consistent results.

How Rivet-Removal Tools Work

Rivet-removal tools are designed to grip the rivet’s mandrel and extract it cleanly. They often come with interchangeable tips to accommodate different rivet sizes and types. These tools are engineered for efficiency, reducing the effort and skill required in manual removal methods.

Steps To Remove Rivets With a Specialized Tool

1. Select the appropriate tip for your rivet size.
2. Position the tool over the rivet head.
3. Squeeze the tool’s handles to grip the rivet.
4. Apply steady pressure to pull the rivet out.
5. If necessary, use pliers to remove any remaining pieces.
6. Inspect the hole for any debris or damage and clean as needed.

Method 3: The Brute Force Approach to Removing Rivets

When precision isn’t critical, or when dealing with stubborn rivets, you may need to use a more forceful method. 

Tools Needed for Manual Removal

• Cold chisel or flathead screwdriver
• Hammer
• Punch (optional)
• Pliers

Step-By-Step Process for Chiseling Out Rivets

1. Position the chisel or screwdriver at the edge of the rivet head.
2. Strike the tool firmly with a hammer to begin separating the head from the shaft.
3. Work around the rivet head, striking at different points until it detaches.
4. Use a punch to drive out any remaining rivet material.
5. Collect all rivet fragments to prevent potential damage or injury.

Precautions and Limitations

• This method can damage the surrounding material, so use caution
• It’s not suitable for delicate workpieces or precision applications
• Wear safety glasses and gloves to protect against flying debris
• Ensure the workpiece is securely fastened to avoid accidental movement

Our Conclusion

Removing rivets can be a straightforward process with the right tools and techniques. Whether you choose to drill them out, use a specialized removal tool, or opt for the manual approach, always prioritize safety and use caution so you don’t damage your workpiece.