Replacing Pop Rivets: A Boat Owner's Guide

Pop rivets are commonly used in boats, but they can be a pain to remove and replace. There are several methods for removing pop rivets, including drilling, grinding, and using a hammer and chisel. Before attempting any of these methods, it is important to take safety precautions such as wearing safety glasses to protect your eyes from sparks and metal shards. When drilling, it is recommended to use a lubricant to reduce friction and heat. Additionally, it is important to maintain a low but steady speed while drilling to avoid slipping and scratching the surface. For grinding, it is crucial to hold the grinder in a steady and fixed position parallel to the surface to avoid scratching. When using a hammer and chisel, be careful not to slip and injure yourself. After removing the pop rivets, you can replace them with bolts and nylon lock nuts or stainless steel screws. It is also recommended to use a sealant, such as 3M 5200 or marine epoxy, to ensure a good seal and prevent future leaks.

Drilling out pop rivets

Preparation:

Before you start drilling, it is important to take the necessary safety precautions. Put on safety glasses to protect your eyes from metal shavings and debris. You should also wear work gloves to guard your hands against sharp edges, and a dust mask to prevent the inhalation of metal particles. If you are using a power drill, ear protection is also recommended. It is also important to securely clamp the workpiece to avoid movement during drilling.

Drilling:

Firstly, select a drill bit that is slightly larger than the rivet's mandrel. Then, use a center punch to create a starting point on the rivet head. Position the drill bit on the center punch mark and start drilling slowly through the center of the rivet head. As you drill through the rivet body, you can increase the pressure slightly. Stop drilling when you feel the rivet head separate from the shaft. Finally, remove any remaining pieces of the rivet with pliers or a punch.

Tips for Successful Drilling:

It is recommended to 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. Lubricating the drill bit with cutting oil can also help to ensure smoother drilling and prolong the life of the bit.

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 is also the best choice when working with delicate materials that could be damaged by more aggressive removal methods. If precision is important, drilling provides control and minimizes damage.

Choosing the right drill bit

First, it is important to understand that the size of the drill bit you choose should match the size of the pop rivets you are replacing. Standard-size pop rivets typically use a 1/8" drill bit, so getting a new, high-quality bit of the same size is recommended. However, it is always a good idea to measure the body diameter of the pop rivets before drilling them out. This ensures that you get the appropriately-sized drill bit and prevents you from removing more material than necessary, creating a bigger hole to fill. A dial caliper can be a handy tool for this purpose.

When selecting a drill bit, opt for one with a V-point rather than a double-cutting point. Additionally, consider using a split-point (135-degree) bit, as this type of bit tends to create a neater divot in the centre of the pop rivet, making it easier for the drill bit to grip.

The length of the drill bit is also an important consideration. Choose a bit that is long enough to penetrate all the way through the pop rivet. It should be able to fit snugly into the divot created by a punch and be secure enough to grip the rivet effectively.

Lubrication is another critical factor when drilling out pop rivets. Drilling through metal creates a lot of friction and heat, so applying a few drops of cutting fluid or lubricant to the end of the drill bit is essential. This will help the bit pierce through the rivet without overheating or getting damaged. Remember to spread the lubricant evenly over the end of the drill bit using your fingers.

Finally, always wear appropriate safety gear when working with power tools. In this case, put on a pair of sturdy safety glasses that fit securely and are rated for drilling or cutting metal. Standard eyeglasses will not provide adequate protection from sparks or flying fragments.

Using a lubricant

Drilling through the rivet will create a lot of friction and heat. To help the bit pierce through the rivet without overheating or getting damaged, add a few drops of cutting fluid, or lubricant, to the drill bit.

Use your fingers to spread the lubricant all over the end of the drill bit. You can find drilling lubricant at hardware stores or online.

Maintain a low but steady speed while you drill through the rivet. Boring through metal rivets is done with pressure rather than speed. Start the drill slowly and maintain a steady pace as you hold the drill against the rivet and apply firm pressure.

Apply more lubricant if the rivet starts to smoke or the drill bit is having trouble picking up speed. Continue to maintain pressure and a steady rate of speed as you drill through the rivet. Eventually, the rivet will be pushed all the way through the hole.

Don’t stop drilling until the rivet is completely removed from the surface.

Safety precautions

Safety should always be a top priority when working with tools and machinery. Here are some detailed safety precautions to follow when replacing pop rivets on a boat:

Wear Protective Gear:

• Always wear safety glasses or goggles to shield your eyes from flying debris, metal shavings, and the rivets themselves.
• Put on protective gloves to avoid injuries when handling tools and sharp metal pieces.
• Consider wearing a respirator or working in a well-ventilated area to avoid inhaling dust or fumes produced during drilling or grinding.

Use the Right Tools:

• Choose a drill that is powerful enough to drill through metal, such as a corded drill, and ensure it is in good working condition.
• Select the appropriate drill bit size for the rivets you are removing. Have extra drill bits on hand in case one breaks.
• Use a punch that matches the size of the rivet's center pin. This is crucial for removing the center pin without damaging the surrounding material.
• Opt for a hammer with a flat head to avoid leaving dents or scratches. Alternatively, use a rubber mallet for a softer touch on delicate surfaces.

Secure the Work Area:

• Clamp or secure the material you are working on to prevent it from moving during drilling.
• Wipe down the area around the rivet with acetone and cover it with duct tape to prevent the rivet from spinning and to protect the surrounding surface.
• If working inside the boat, cover or protect any sensitive equipment or surfaces to avoid accidental damage.

Seek Professional Help:

If you are unsure about the process or feel uncomfortable handling the tools, consider seeking professional assistance. Some tasks may require specialized tools or expertise to ensure a safe and proper repair.

Follow Manufacturer's Instructions:

When using a rivet gun or other specialized tools, carefully follow the manufacturer's instructions for setup and use to ensure your safety and the best results.

By following these safety precautions, you can help ensure a smooth, efficient, and accident-free process when replacing pop rivets on your boat.

Grinding the rivet off

Step 1: Put on Safety Gear

Before you begin, it's important to prioritise your safety. Grinding metal can generate sparks and shards of metal that can be hazardous. Make sure to wear strong safety glasses that are rated for metalwork to protect your eyes.

Step 2: Position the Grinder

Hold the grinding wheel parallel to the surface where the rivet is attached. Approach the head of the rivet with the wheel of the grinder, positioning it as close as possible to where the head of the rivet meets the surface. Be careful not to wedge the wheel beneath the head of the rivet before turning it on, as this can break the wheel and send shards flying.

Step 3: Start Grinding

Turn on the grinder and slowly move it towards the rivet until you make contact with the head. Maintain a steady position as the grinder cuts through the metal. If you feel resistance, hold the grinder in place to allow it to finish cutting through before continuing.

Step 4: Punch a Dent

Once you've removed as much of the rivet head as possible, use a pin, prick, or centre punch to create a small dent in the centre of the remaining rivet. This will help your drill bit grip the metal when you start drilling. You may need to strike the punch a few times to create a deep enough divot.

Step 5: Lubricate and Drill

Lubricate your drill bit to prevent overheating and damage. Choose a drill bit that is slightly smaller than the divot made by the punch and drill a pilot hole through the rivet. Then, switch to a drill bit that is just under the same size as the rivet and lubricate it as well. Fit the bit into the pilot hole and apply firm pressure while drilling at a steady pace to push the rivet through.

Remember to always wear safety gear and work carefully when grinding and drilling to avoid accidents and damage to the surrounding surface.

Frequently asked questions