How do you remove a broken blind rivet?

Removing a broken blind rivet can be a challenging yet necessary task in various repair and maintenance scenarios. As a blind rivet supplier, I've encountered numerous customers facing issues with broken rivets and seeking effective removal methods. In this blog post, I'll delve into the step - by - step process of removing a broken blind rivet, along with some useful tips and considerations.

Understanding Blind Rivets

Before we jump into the removal process, it's essential to understand what blind rivets are. Blind rivets, also known as pop rivets, are fasteners used to join two or more materials together. They are particularly useful when access is only available from one side of the materials being joined. A blind rivet typically consists of a rivet body and a mandrel. When the mandrel is pulled, it deforms the rivet body on the blind side, creating a secure joint.

There are different types of blind rivets available in the market, such as the Round Semi Tubular Steel Rivet and the DIN7337 Aluminum Blind Rivet. Each type has its own unique characteristics and applications, but they all share the basic principle of installation and potential for breakage.

Reasons for a Broken Blind Rivet

A blind rivet can break for several reasons. One common cause is over - tightening during installation. If too much force is applied to the mandrel, it can snap, leaving a broken piece inside the rivet body. Another reason could be the use of a low - quality rivet that is prone to breakage under normal stress. Additionally, environmental factors such as corrosion or excessive vibration can weaken the rivet over time, leading to breakage.

Tools Required for Removing a Broken Blind Rivet

To successfully remove a broken blind rivet, you'll need a few tools. Here's a list of the essential tools:

1. Drill and Drill Bits: A drill is the most commonly used tool for removing a broken blind rivet. You'll need a drill bit that is slightly smaller in diameter than the rivet body. For example, if you're dealing with a 3/16 - inch rivet, a 1/8 - inch drill bit should work well.
2. Center Punch: A center punch is used to mark the center of the rivet before drilling. This helps prevent the drill bit from wandering and ensures a more accurate hole.
3. Pliers: Pliers can be used to grip and pull out the broken mandrel or the remaining rivet body after drilling. Needle - nose pliers are particularly useful for this task.
4. Hammer: A hammer is used in conjunction with the center punch to create a small indentation on the rivet.

Step - by - Step Process of Removing a Broken Blind Rivet

Step 1: Mark the Center of the Rivet

Use the center punch and hammer to create a small indentation in the center of the broken rivet. This will help guide the drill bit and prevent it from slipping off the rivet surface. Place the center punch on the rivet and gently tap it with the hammer until a visible mark is made.

Step 2: Drill a Hole in the Rivet

Insert the appropriate drill bit into the drill. Make sure the drill is set to a slow speed to avoid over - heating and damaging the surrounding material. Place the drill bit on the marked indentation and start drilling. Apply gentle pressure and let the drill bit do the work. Drill through the center of the rivet until you reach the other side.

Step 3: Remove the Broken Mandrel

Once the hole is drilled, use the pliers to grip the broken mandrel and pull it out. If the mandrel is stuck, you may need to wiggle it gently from side to side to loosen it. In some cases, the mandrel may break off during the drilling process, and you'll need to use the pliers to remove the remaining piece.

Step 4: Extract the Rivet Body

After removing the mandrel, use the pliers to grip the rivet body and pull it out. If the rivet body is still firmly in place, you can try using a larger drill bit to enlarge the hole slightly. This will weaken the grip of the rivet body on the material, making it easier to remove.

Step 5: Clean the Hole

Once the broken blind rivet is removed, use a deburring tool or a file to remove any burrs or rough edges from the hole. This will ensure a clean surface for the installation of a new rivet.

Tips and Considerations

• Safety First: When using power tools such as a drill, always wear safety goggles to protect your eyes from flying debris. Also, make sure to follow the manufacturer's instructions for using the tools.
• Select the Right Drill Bit: Using a drill bit that is too large can damage the surrounding material, while a bit that is too small may not effectively remove the rivet. Choose a drill bit that is the appropriate size for the rivet.
• Test on a Scrap Piece: If you're unsure about the drilling process or the effect it may have on your material, it's a good idea to test the removal process on a scrap piece of the same material first.

When to Seek Professional Help

In some cases, removing a broken blind rivet can be extremely difficult or dangerous. If the rivet is located in a hard - to - reach area or if the material is delicate and easily damaged, it may be best to seek the help of a professional. A professional has the experience and tools necessary to safely remove the rivet without causing further damage.

Conclusion

Removing a broken blind rivet is a task that requires patience, the right tools, and some basic knowledge of the process. By following the steps outlined in this blog post, you can effectively remove a broken blind rivet and prepare the area for a new rivet installation.

As a blind rivet supplier, we offer a wide range of high - quality blind rivets, including the Round Semi Tubular Steel Rivet and the DIN7337 Aluminum Blind Rivet. If you're in need of blind rivets for your projects or have any questions about our products, please feel free to contact us for a procurement discussion. We look forward to assisting you with your rivet needs.

References

• "Rivets and Riveting Handbook" by Industrial Press Inc.
• "Fasteners: Design and Engineering Handbook" by William H. Ailor.