Light Plane Philosopher
- Dec 16, 2007
- Port Townsend WA
That's what I suggested post 11. Deburr using drill and 400 grit sandpaper?One more idea to try. I have not tried this myself, but just brainstorming.
Get a pin punch or piece of music wire the diameter of your rivet hole. Round the end so it doesn't damage the aluminum. Put it in the cordless drill chuck.
Put a set screw style drill stop (that's a "wheel collar" for us model airplane builders) on the wire about 3/8 or 1/2 inch from the rounded end.
Cut a very small round piece of Scorchbrite, maybe 3/8 of an inch diameter. Just larger than the head of the rivet.
Pierce the wire through this small Scotchbrite disk in the middle.
Put the round end of the wire in the rivet hole as a pilot, and turn the small Scotchbrite as you push the tool down onto the aluminum sheet.
This should minimize the scratching and scuffing of the aluminum to a small area around the hole itself.