Difficulty replacing rivets in an aluminum hull.

[ShoestringMariner]

Hey everyone, I’ve run into some troubles replacing some rivets on an aluminum hull.
Some of the rivet heads on my hull were badly corroded, I had difficulty finding centre or in some cases, I drilled the hole crooked. Punching out the remaining rivet has left an oblong hole on the inside.
How do I correct for this? I’m getting rivets that won’t tighten or crush properly. Go larger diameter rivet? Use a longer rivet and a washer? (Plus drizzle rivet with 3m 5200?) close

I’m also getting a nasty smile on some of the rivet heads assuming either from my cheap air hammer,

im using 5/32” 2000series rivets, brazier head rivets. Should I consider using a softer alloy on the messy holes so it will expand in the oblong hole better?

thanks in advance

 

[ShoestringMariner]

Marine Tex the holes, re-drill when hard and use blind, closed end pop rivets with 3M 5200?

 

[ShoestringMariner]

Anyone? I’d really like to get this thing underway. Parts take another week ++ to order. I still have to put floors in this boat. Good grief I won’t be fishing till fall!!

 

[captainnate]

I'm working on some hull patches on my 1972 Starcraft Nova aluminum hull. I've been using this rivet removal tool to get started: https://duckduckgo.com/?q=remove+rivet+center+drill&iax=images&ia=images&iai=https://aircraft-tool.com/shop/dbpics/large/1341a.jpg It gets the drill pretty close to center. I try not to be too aggressive. Then I switch to an extra wide drill bit to remove most of the rivet head material. Once the rivet head comes off I punch out the back of the rivet.

As far as the oblong holes go, I like the idea of a larger rivet with 5200. Sorry, I don't have enough experience to say for sure.

 

[Star64!]

Using 1/4” 1100 rivets with cheap air hammer. 5/32 brazier bit and sealer. Rivets are forming nice looking shop end but a bit erratic sizes. When practicing with longer rivets was difficult to get them to form even shop head. Shaft would tip. Not sure about being water tight but they look good.

drilling out old rivets was simplified by buying $70 rivet removal tool from aircraft tool supply. Instructions with tool would be nice. Developing own method but centering bit is simplified and tool does this well. Final removal usually requires 1/8” punch but holes are not oblonged. Be careful