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

Pro Tip: When choosing any fastener — rivets included — TOH general contractor Tom Silva’s rule of thumb is to select fasteners that are two and a half times the thickness of the material being attached. Always make sure the fastener won’t go clear through the substrate on the other side.

Hand Rivets vs. Pop Rivets: While pop rivets are convenient for quick DIY repairs like gutter work and sheet-metal projects, hand-set rivets offer superior holding power and don’t spin on their axis. As demonstrated on a This Old House project assembling copper gas lights, craftspeople still hand-rivet pieces together using aviation-grade tools — the same technique used to build airplanes — when the joint needs to withstand heat or vibration that would compromise a pop rivet or soldered connection.

From the Field: Drew, a copper artisan featured on This Old House, explains why hand rivets remain essential for certain work: “The only other ways to adhere a copper are soldering or a pop-riveting. Soldering of course would come apart with the heat of the gas light so we don’t use that. And then, pop rivets are a little weak and kinda spin on their axis, so they’re not a good solution either but, the way they build airplanes is the way we build lights. With aviation technology and tools.”

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. 

Choosing the Right Drill Bit: Twist drill bits are the go-to for rivet removal, but understanding their grades matters. High-speed steel (HSS) bits come in different coatings—some are designed to last longer, while higher-end options can withstand the heat generated during drilling. As TOH has covered, heat from drilling into metal “actually starts to form the metal a little bit and dull the blade pretty quickly.” To preserve your bit’s edge when drilling out steel rivets, use a lubricant—it keeps the cutting edge cooler and sharper.

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

Pro Tip: Before you start drilling, use a center punch to make a small dimple in the center of the rivet head. As noted in the This Old House drill bit guide, a center punch is “a pointed tool for making a tiny dimple in metal to locate a drill bit and help start the hole.” This prevents the bit from wandering across the rivet’s smooth surface and ensures a clean, centered removal every time.

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

Leverage Matters for Stubborn Rivets: Once you’ve drilled through or weakened a rivet, you’ll often need a pry bar or flat bar to pop it free. TOH general contractor Tom Silva recommends keeping bars of varying lengths on hand for extraction work: “The rule is that the longer the bar is, the more leverage you have—that means you don’t have to work as hard.” A small flat bar is ideal for prying out loosened rivets without damaging the surrounding material.

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.

Bit Sizing Matters: While many guides suggest using a bit slightly larger than the rivet’s mandrel, TOH’s Tom Silva emphasizes that “the drill bit size is the exact same size as the rivet.” Using a matching bit lets you cleanly remove the rivet head without enlarging the hole in your workpiece — critical when you need to reinstall new hardware in the same location.

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.

Pro Tip: When drilling out rivets near fragile materials, take extra care with your depth. As Tom Silva cautions during a window sash lock replacement: “I wanna make sure I drill out the rivet, but I don’t wanna go too deep and damage or hit the glass because I could break the glass and damage the seal between the insulated panels.” Consider placing a depth stop on your drill bit or wrapping tape around it to mark your maximum depth.

Stepping Up Bit Sizes: As Norm Abram explains in his approach to drilling through steel, “If progress is slow, first drill a smaller hole before stepping up to the final bit.” For stubborn rivets — especially in thick steel — start with a smaller pilot bit and then enlarge to your target size. Norm also advises against forcing the bit: “Trying to muscle the bit will cause it to overheat, lose its temper, and stop cutting.” A center punch dimple at the start prevents the bit from skating across the rivet head.

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.

Technique Detail: When using a cold chisel for forceful removal, hold the chisel with the bevel side down so you can control the direction of the cut. As demonstrated on Ask This Old House, holding the chisel bevel-up can cause it to dive into the material, risking the removal of too much material at once. With the bevel down, you can use it as a fulcrum to push down and make a controlled, level cut across the surface.

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.