When drilling out a rivet, use a drill
- larger than the rivet hole.
- same size as the hole.
- smaller than the rivet hole.
Explanation from PART66Online
A rivet is drilled out on the axis of the manufactured head, only to the base of that head, with a drill smaller than the rivet hole so that the drill cannot reach the wall of the parent hole. A drill the size of the hole, or larger, cuts the hole itself, destroys its accuracy and forces the repair up to the next rivet size.
avionics asked · 1 Feb 2017
according to CAAIP it should be smaller than the shank of the rivet when removing rivet.
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