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Jonno1968

Member Since: 24 Oct 2013
Location: Leicestershire
Posts: 245

2010 Defender 90 Puma 2.4 XS CSW Orkney Grey

How do you remove pop rivets??,

I am replacing the chequer plate all round from silver to black as its a bit less blingy for the colour of my vehicle (nothing against shiney silver!) and it has got discoloured. But....I have drilled the tops off the pop rivets, removed the chequer, and left with lots of sticky out bits. I can't tap them thru as that dents/distorts the surrounding metal and if I try and drill that is sometimes ok but on occasions the drill slips off......

is there a different way of doing this? I have stopped pending some miracle advice on here!

Oh...and a word of warning if you do this replacement task the new plate won't necessarily be the same size as the old so watch out for old holes showing!!

28th Aug 2015 7:26pm

RRUK
Site Supporter

Member Since: 31 Mar 2010
Location: Leicestershire
Posts: 2014

It's an issue when replacing chequer plate, that the holes don't line up. You often end up drilling more holes, but generally if your wings have had plate put on, you have to stick with it unless you replace the wings.

The trick is to pick a drill but large enough to allow the pop rivets to fall out or be pushed through easily. If you can get access underneath (possible for most of the holes) you can use pliers to pull he remaining bit out.

Thank your lucky stars they were not fixed with the sunken Allen heads and bolts! 2016 D4 HSE

1998 110 TUM HS FFR Hard Top XD WOLF

1982 Series 3 SWB Petrol

28th Aug 2015 7:37pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 16884

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

It helps if you punch out the stub of the steel expander before doing any drilling (unless it's a sealed rivet when you can't do this). Then drill the head off with a bit the same size as the original hole, or slightly larger. As soon as the head is off, stop and change to a bit slightly smaller than the original hole, and drill to just below the panel surface. Usually this will push the remains out, if not give it a gentle tap with a punch.

Usually it is the steel fragment in the rivet that causes the problem drilling, so get rid of it first.

28th Aug 2015 8:11pm

mk1collector

Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

Put the chequer plate back on and drill through the rivets, then if you slip you only scratch the old chequer plate Ray
My build thread
http://www.defender2.net/forum/topic17615.html

28th Aug 2015 9:22pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 19579

^^^^ Very true, or in case the bit randomly disintegrates!

I'd keep the bits as small as possible to get them out and avoid enlarging the holes at all costs or eventually if your not careful you'll need boots though it instead.

28th Aug 2015 9:26pm

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