Ode to a Rivet
by I Bleed Freely

A small bit of steel rounded on each side
Beat into place by workmen with pride

A tiny little rivet, its really not much
Holding steel together and brackets'n such

In 1954 did they know it would last?
That 50 years later it would kick my ass?

I pounded that rivet half of the night
I pounded that thing with all of my might.

My fingers were swollen from missed hammer blows
When will that rivet move? Nobody knows!

Finally the head broke and flew 'cross the room
I shouted for joy, I howled at the moon!

But wait, where is the hole? I checked it with care
But the shaft remained, the shaft was still there.

So I drilled through the bastard, I drilled and I cussed
Until nothing remained but two broken bits, and rivet dust.

Sucess, Sucess! I have beaten it, I have won!
Then I turned and I counted, 30 more needed done.

 

(with apologies to all real poets every where)

I believe everyone who has done a restoration or modification of an original Willys chassis will agree that the biggest pain in the arse is removing rivets. I dedicate this page to all those people and the bruises and blood blisters they have so proudly earned. For those who have not earned this honor yet, pay attention, my revised method (below) will save you HOURS as well as pain.

Center punch the rivet, if it is in an awkward position use your cold chisel to slot across the top. Use PLENTY of light oil as you drill (spray oil like WD40 is great when working on side rails).
Drill through the rivet using a smaller bit.  I used a 7/32" cobalt bit from Craftsman.  The quality bit and the oil are the real secrets here. Redrill through using a 3/8" bit, the rivet is slightly larger then 3/8 so it's OK if the drill has wandered and or you are drilling at a slight angle.
Used the cold chisel to knock off the head of the rivet. The bottom will usually fall out when the head is removed, sometimes it has already fallen out.
Hold your mouse over each picture for a detailed description, click on the picture for a slightly closer look.