Rivet Hole Repair

[dmcinfo]

In getting my AS ready for polishing, I removed the AIRSTREAM name plates on the front and rear. When drilling out one of the rivets I must not have had the drill lined up properly and I ended up with a larger hole (see pic). Unfortunately, it was at one of the corners and I am concerned that the nameplate will eventually pull up at this location.

My question: Is it possible to repair so that a rivet will go in securely at this spot or do I just live with the mistake and use lots of adhesive?

Any suggestions will be most appreciated.

[kevin242]

You could use a rivet with a larger diameter shank, but the same size head as the other rivets that hold the nameplate on (first choice...).

Another option is to put a dab of "JB Weld" behind the nameplate where the rivet hole is and then put the rivet through the hole and secure it (second choice). I suspect the JB Weld will seal & secure it OK. It's not like it bears any stresses really.

[wkerfoot]

You could use an olympic rivet at all four corners. Properly finished they look almost like bucked rivets. Or if you have the inside skin off put a small piece of aluminum inside the bucked rivet.

Bill

Originally Posted by dmcinfo

In getting my AS ready for polishing, I removed the AIRSTREAM name plates on the front and rear. When drilling out one of the rivets I must not have had the drill lined up properly and I ended up with a larger hole (see pic). Unfortunately, it was at one of the corners and I am concerned that the nameplate will eventually pull up at this location.

My question: Is it possible to repair so that a rivet will go in securely at this spot or do I just live with the mistake and use lots of adhesive?

Any suggestions will be most appreciated.

[truckasaurus]

Easy fix, use a washer behind the rivet.

[Aage]

A SS or AL washer, I guess...

[azflycaster]

Since a name plate will cover this hole in the skin, just use an olympic rivet. The legs of the rivet are more then wide enough when extended to get a good grip.

[dmcinfo]

In the future, what can I do to prevent making the same mistake?

[wkerfoot]

Not to be a smart aleck, but be careful.

Bill

Originally Posted by dmcinfo

In the future, what can I do to prevent making the same mistake?

[PetervB]

an experienced aircraft worker gave me some advice--
1. use a machinists punch to mark the center of the rivet dome; remove paint or other materials first. get this as accurate as possible so the drill bit doesn't wander.
2. use a small drill say 3/32 or 1/16" to drill through the dome, but hardly into the shank.
3. switch to a 1/8" drill to widen the hole, but stop before going past the head. Don't drill into the shank at all. This will eliminate damage to the sheet metal parts
4. insert a 1/8" punch or old 1/8" drill( the smooth part where the drill chuck grabs it). rock the punch/bit back and forth until the head of the rivet breaks off.
5. punch out the shank.

This would be best practice for a high strength repair. For cosmetic rivets I skip the 3/32 drill step. It takes practice and judgment to get the 1/8" hole the right depth. If the hole isn't centered the head won't break off clean and a small chisel must be used to knock the rest off. That will probably damage the sheet metal..
Vintage Trailer sells 5/32 shank 1/8 head rivets.. clean up the holes with a #20 drill bit which will alleviate the damage.

[reinergirl]

If the interior skin is out, I've had good luck taking a sharp chisel, knocking off the stem in the back and popping the rivet head out with a nail set.