41 00... Riveting Aluminium Parts

1.0 Recommended tools and equipment 

• Stud welding apparatus (refer to Service Information 5 03 03 975) with gas bottle containing inert gas (82 % argon, 18 % CO₂ ).
• Stainless steel stud
• Universal riveting tool (refer to Service Information 5 03 03 975)
• Hand riveting tool for blind rivet nuts and blind rivet bolts .

2.1 Extracting punch rivets: 

• Grind off paint and dark grey coating of punch rivets.
• Position bolt centrally on the rivet and weld on vertically. The area in which the bolts are welded on should be between the two grounding terminals. Position both terminals, if possible, on the top side of the metal plate on which the rivet is located.
• Extract bolt with welded-on rivet using universal riveting tool. Use a large plastic nose piece if not otherwise specified in the repair instructions. Check plastic nose piece prior to use for wear.
• Plastic nose piece must rest on sheet metal all round; if necessary, grind off plastic noise piece in collision area.

  Do not push riveting tool forcefully onto special-steel bolts.

  Do not use riveting tool to bend special-steel bolts.

• Pay particular attention to central positioning of the bolt when using the small plastic mouthpiece.
• Follow the equipment manufacturer's instructions for use.

2.2 Drilling out punch rivets: 

Only if extraction proves repeatedly unsuccessful or the rivet cannot be accessed with the universal riveting tool.

• Drill out rivets with a 6 mm dia. carbide drill bit.
• Punch rivets can be drilled out on both sides. When drilling from the protruding rear side, spot-drill the rivet shank only and remove the rest with a rivet punch.
• Use a drift punch to remove all punch rivet remnants in the aluminium (risk of corrosion).
• Clean vehicle to remove all traces of chips (risk of corrosion).

2.3 Drilling out blind rivets: 

Only when a part is repeatedly replaced.

• Drill out rivet head only  with 6 mm dia. metal drill bit. Knock out rivet remnants with a drift. Use existing 6.7 mm hole for blind rivet.
• Clean vehicle to remove all traces of chips and rivet remnants (risk of corrosion).

3.0 Blind riveting in conjunction with bonding 

• The standard punch rivets are always replaced by blind rivets in conjunction with bonding.
• The required strength of the connection is only achieved through a combination of bonding and riveting.

4.0 Setting blind rivets: 

• Refer to repair instructions for rivet size (size 13 or size 15 with 6.5 mm dia. or 4.0 mm dia.).
• Position blind rivets in the same locations as the extracted punch rivets. Exceptions are described in the relevant repair instruction. If necessary, carry over the positions of the rivets to the new component.
• Drill holes (4.2 mm dia. for 4 mm rivet and 6.7 mm dia. for 6.5 mm rivet).
• Apply adhesive.
• Insert blind rivet. The riveting direction is the same as the line of vision in the picture shown in the repair instruction (e.g. from wheel arch into engine carrier).
• Universally rivet blind rivet with riveting tongs.
• Seal blind rivet with PU sealing material (risk of corrosion).
• Seal cavities with preserving agent (risk of corrosion).

5.0 Setting blind rivet nuts and blind rivet bolts: 

• Standard stud welding is always replaced by blind rivet bolts.
• Drill holes (0.2 mm larger than the outside diameter of the blind rivet nuts or blind rivet bolts).
• For corrosion reasons, blind rivet nuts and bolts must have a special coating .

  Use the blind rivet nuts and bolts supplied in the case of the manual riveting tool for steel only! 

• Insert blind rivet nuts or bolts and tighten down with the riveting tool.
• It will no longer be possible to set a blind rivet nut if the drilled hole is too big. In this case, set a clip nut . This nut tightens itself automatically when screwed to the component.
• Seal blind rivet nuts and bolts with PU sealing material (risk of corrosion).