Avdel Avdelok Removal

[SierraV6]

Afternoon all.

I need to remove a large number of Avdelok fasteners and only have limited access to the stem side. So far I’ve been grinding the heads off which is tedious, dirty, and inevitably results in the occasional gouge in the outer panels which I plan to reuse…. Avdel and Huck both make a splitter which removes the collars but they’re expensive (very!). It did get me thinking though about other ways to remove them. I’m leaning towards trying a heavy duty metal cutting blade in my Fein multi tool and cutting through the collars, I need to check it will reach through the access holes though. The other option is grind a slot in an SDS+ chisel bit deep enough to clear the stem and try chiselling through them using my Hitachi drill. I’m not sure if the collars are as hard as the rivets themselves (which are hard!)?

Any thoughts or ideas would be welcome!

 

[Shox Dr]

TPITA. If you can't get to the backs then grinding the head off is about your only option.

How does the splitter work?

 

[Hitch]

Ive always removed Huck bolts with a cutting disc and punch.
There are cutters for removing the collars, they look like mag drill bits, different cutter for each size though, had a set at work years ago.

If you're only removing 1/4" ones, a small mag drill cutter may well work, (in a holder for a cordless drill) the cutter would centralise on the shaft, and cut the back of the collar, like the Huck cutters.

Wonder if a decent nut splitter would do it followed by a good smack with a chisel ... I guess access is a problem for that.

 

[SierraV6]

TPITA. If you can't get to the backs then grinding the head off is about your only option.

How does the splitter work?

I can get to the backs but only through the access holes which are there to allow them to be installed in the first place. The holes are a decent size actually but you can’t get a grinder in.

The splitter is basically a large hydraulic (or smaller pneumatic) nut splitter.

Ive always removed Huck bolts with a cutting disc and punch.
There are cutters for removing the collars, they look like mag drill bits, different cutter for each size though, had a set at work years ago.

If you're only removing 1/4" ones, a small mag drill cutter may well work, (in a holder for a cordless drill) the cutter would centralise on the shaft, and cut the back of the collar, like the Huck cutters.

Wonder if a decent nut splitter would do it followed by a good smack with a chisel ... I guess access is a problem for that.

Thanks, I’ve just googled those cutters and they may be the answer! They are only 1/4” ones as it happens, there are a small number of larger ones to contend with but for the number involved I don’t mind grinding those.

A nut splitter could work although as you say access is an issue. As per my reply to @Shox Dr the proper tool is to all intents and purposes a posh nut splitter.

 

[SierraV6]

A quick update for those interested!

I tried the nut splitter method. It works but it’s fiddly, both in terms of access to tighten the tool itself, and what you’re left with…. It splits the collar relatively easily, but it doesn’t release enough tension to then knock the pin through. That leaves two options, mess about opening it up with a small chisel or split it again on the opposite side (which is how the proper tool works from what I can make out). Unfortunately it’s just not feasible to do this a few hundred times over, it is however useful to know that it can be done, so well worth the experiment!

My next idea (and I don’t know why I didn’t think of this before) involves a die grinder and a cylindrical burr (with no end cut) which I think will eat the collar away in no time. I’ll let you know how it goes….

 

[SierraV6]

A further update for those interested (probably nobody so apologies!).

The die grinder works quite well, it’s slower than using an angle grinder but unlike an angle grinder it actually fits through the access holes. It also obviously doesn’t create sparks which is one of the things I’m trying to avoid in the first place so I’m happy.

However, for the rivets that don’t have restricted access I think I’ve found the ultimate remover (short if buying the proper tool) in the form of my Bahco 600mm bolt cutters. They basically work in the same way as the proper tool by cutting through the collar from two side so it’s not surprising really, I just hadn’t thought of trying it before. It’s a shame they don’t fit through the 60mm access holes or I’d use them all the time, I could try smaller ones but I’m not sure they’ll generate enough force.

I promise not to talk about Avdeloks for at least a week now!

 

[Hitch]

Did you try a broach cutter?

 

[DanZac]

Just out of interest @SierraV6 and my apologies if you've already told us but what are you working on?

I've only ever come across Avedelocks in the aircraft world so I'm intreagued where you've found some.

 

[Hitch]

Just out of interest @SierraV6 and my apologies if you've already told us but what are you working on?

I've only ever come across Avedelocks in the aircraft world so I'm intreagued where you've found some.

They're very common in the commercial vehicle body sector.

 

[DanZac]

They're very common in the commercial vehicle body sector.

Every day's a school day as they say.

 

[SierraV6]

Did you try a broach cutter?

No not yet. It’s a great suggestion though so I may give it a go, thanks.

Just out of interest @SierraV6 and my apologies if you've already told us but what are you working on?

I've only ever come across Avedelocks in the aircraft world so I'm intreagued where you've found some.

I’ve not actually said, but it’s a Leyland National bus. They make extensive use of the 1/4 and 3/8 inch Avdeloks. The structure is very aircraft-like now you mention it, basically a self supporting tube/box with no chassis. It’s interesting and quite clever but not the easiest thing to work on!