Originally Posted by David Paule
To remove a rivet, I like to use a smaller drill to go about 2/3 of the way through. For this, I use a drill bit ten numbers smaller than is appropriate for the rivet. So for a -4 rivet, I'd first use a #40 drill.
Then I drill just the head off with teh correct drill. For this example, I'd drill just the head with #30. Then pop the head off and use a punch that's 3/32" diameter, matching the #40 hole, to knock the body out. The smaller drill weakens the body and makes it easier to punch out.
I've basically done the same thing to remove long (-8, -9) rivets in the exact same locations as the OP in my RV9 HS, and it works a treat. I often found when I put the #30 drill in after drilling through with the #40 that the head snaps off when the drill bit "grabs" it. I even have one I drilled a long way through with a #40 so there's just a thin-walled tube about 10mm long attached to the shop head! As others have mentioned, go slow, pay attention, and make sure the drill is dead in line with the rivet.