What is the generally recommended method for removing a solid shank rivet?

The generally recommended method for removing a solid shank rivet is to drill to the head base with a slightly smaller drill. This approach is effective because it allows for precise removal of the rivet without damaging the surrounding structure. By drilling down to the head of the rivet, the head can be removed, and then the remaining shank can typically be pushed or extracted from the hole.

Utilizing a drill that is slightly smaller than the rivet diameter ensures that you do not oversize the hole, which could weaken the surrounding material and affect the integrity of the structure. This method is widely accepted in the maintenance and repair of aircraft as it balances effectiveness with minimizing potential damage to the components involved.

The other methods mentioned, such as cutting with a saw or using a hammer to push it out, can lead to unintended damage or complications. Heat may alter the characteristics of the material, again risking damage. Therefore, drilling is the most precise and safest way to remove solid shank rivets in sheet metal structures.