Drill the appropriate-sized holes for rivets that will be installed. Make sure the holes go straight through the materials at a 90 degree angle by holding the drill perpendicular to the material being drilled.
Debur the rivet holes to remove any sharp pieces or stray uneven surfaces.
Countersink the rivet holes using a countersink bit that attaches to your drill. Make sure to hold the drill at a 90 degree angle to metal being drilled. The countersink bit should have an automatic stopping feature.
Inspect the countersunk holes to ensure that they are not "knife-edged." The edge of a knife-edged countersunk hole comes to a sharp, thin edge. These thin edges weaken the metal and can lead to fatigue crack and can also cause rivets to move within the rivet holes
Press a rivet unto the newly countersunk hole. The rivet should sit flat and flush. If the rivet head is higher than the surface material then countersink the hole slightly deeper. Continue until the rivet sits flush with the material.
Drill the rivet holes to the next larger size that your installation or repair documentation allows for any countersunk rivet holes that are crooked or poorly shaped. Make sure any larger holes still achieve proper rivet spacing.
Inspect countersunk holes again using the appropriate sized rivets. Be careful not to enlarge any unacceptable holes too much. If any of the holes become too large or if rivet spacing falls out of acceptable limits, the parts being riveted may have to scrapped and completely remade.
