How to remove a pop rivet without damaging it

An accessory to replace, a metal bracket to salvage, an assembly that has developed play: sometimes you need to remove a pop rivet without sacrificing the surrounding parts. The right approach involves identifying the fastener, securing the assembly, and then separating its head through centered and controlled drilling. This is not a screw: trying to unscrew it or pry it out with a screwdriver is mostly likely to mark the substrate.

This guide concerns standard blind rivets on small non-structural metal assemblies. It does not automatically apply to solid rivets, safety fasteners, load-bearing elements, or pressurized equipment. For these, follow a procedure validated by their manufacturer or entrust the disassembly to a professional.

1. Identify the rivet and its diameter before starting

An installed blind rivet typically features a visible flange and a small center corresponding to the broken mandrel. Its body passes through the parts and deforms behind them to clamp them. Do not confuse the outer diameter of the flange with that of the body: using a drill bit as wide as the entire head can gouge the surrounding sheet metal.

Look for the rivet's part number or compare it with an identical new one. A head that appears to measure eight millimeters does not mean the body measures eight millimeters. If no reliable information is available, measure what is accessible and ask for advice before choosing a large drill bit "just to be sure."

Also observe the rear access. A fragment could fall into a closed profile, remain in a mechanism, or hit a cable. Unplug and isolate any relevant equipment. Support the part that will be freed: removing the last rivet should never cause it to fall.

2. Choose a metal drill bit, not just an approximate diameter

Use a drill bit intended for metal, in good condition, with a diameter that complies with the procedure for the rivet in question. The material matters: an aluminum rivet, its steel mandrel, and a stainless steel rivet do not behave the same way. A dull point pushes and heats up instead of cutting properly.

The Makita D-72833 set offered on Manuzen contains gold-colored metal drill bits. Pay attention to the shared product page: D-72861 designates the wood variant, which must not be chosen for this operation. Verify the selected option and the diameter actually required. An assortment does not necessarily contain the intermediate diameters requested by a manufacturer.

Therefore, keep this rule in mind: if the specified diameter is missing, get the correct drill bit rather than intentionally enlarging the hole. Also check that the drill bit shank fits your drill chuck. Assembly and any accessory changes must be done with the battery removed or the machine unplugged.

3. Secure the parts and prepare the center of the rivet

Set up the assembly on a clear workbench. Blocks protect its finish and allow for a free zone behind the fastener. Clamp the two parts with a vise or clamps, without crushing a hollow profile. Check their stability by hand before plugging in the machine; they must neither pivot nor vibrate.

Wear safety glasses, tie back hair, and keep loose sleeves, jewelry, and hands away from rotating parts. Never hold a small piece of sheet metal with your fingers during drilling. Gloves can be used to handle sharp edges when stopped, but they must not be able to get caught by the drill bit.

Clean the head to distinguish its center. Depending on the rivet and its instructions, the remainder of the mandrel must be pushed back with a suitable pin punch before drilling. The substrate must be properly supported: if the mandrel resists or the metal sheet flexes, stop. Striking harder is not a universal solution.

4. Drill the rivet head without enlarging the hole

Set the drill to rotation mode only, without hammer action. Present the drill bit in line with the rivet, perpendicular to the surface. Start gradually with a slow feed to maintain centering. Then adapt the settings to the material, diameter, and the drill bit manufacturer's recommendations; there is no single speed for all assemblies.

The first goal is to separate the flange, not to blindly drill through everything behind it. Take control breaks. As soon as the head comes free, release the trigger and wait for a complete stop. Do not pull a metal ring stuck on a drill bit that is still spinning.

Is the rivet spinning with the drill bit? Stop the operation: check the clamping, centering, and cutting condition. Do not tilt the drill to "catch" the edge. If the drill bit deviates, heats up significantly, or stops advancing, resume the diagnostic instead of abruptly increasing pressure.

5. Remove the fragments and check the substrate before reassembly

Once the head is separated and the tool is powered down, remove the rest of the rivet according to its construction. It can sometimes be pushed out with a suitable tool, without putting force on the metal sheet. If the body remains stuck, consult the corresponding procedure rather than prying between the parts. Collect accessible waste before moving the assembly.

Brush away chips while stopped, then examine both faces. The hole must remain round, without cracks or tearing. Remove only troublesome small burrs with a suitable tool, without turning the opening into a funnel. An ovalized hole, significant corrosion, or torn sheet metal require a defined repair, not just a larger rivet placed at random.

Do not reuse the removed rivet. Before reassembly, choose a new fastener compatible with the materials, total thickness, and the inspected hole. Our guide on installing blind rivets with a drill details this distinct step.

To remember: identify, choose, clamp, drill just enough, and check. A good result is not just a removed rivet: it is a substrate that is still usable. Before your repair, check out the Makita drill bits and verify the D-72833 option.

Technical references: GESIPA advice on removing blind rivets and Makita manufacturer part number D-72833. Instructions specific to your assembly remain the priority. Illustrative visuals generated by AI; inset photo taken from the product page.