Body Component Replacement; Drill Out Metal Rivet - Cushman SHUTTLE 4X Technician's Repair And Service Manual

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
BODY
In the following text, there are references to removing/installing
bolts etc. Additional hardware (nuts, washers etc.) that are
removed must always be installed in their original positions
unless otherwise specified. Non-specified torques are as
shown in the table in Section A.
General
To prevent possible injury or death from
battery explosion, batteries should always be
removed before any servicing that will
generate sparks.
It is important to use a sharp drill bit when
removing the rivets on the side of the
vehicle. Extreme care must be used when
drilling out the rivets located in the front of
the body and the bottom side of the body.
Excessive pressure could result in the drill
bit being forced through the body panel
a n d p e n e t r a t i n g a b a t t e r y . A s e x t r a
protection, it is recommended that a
protective piece of sheet metal be placed
between the battery and the rivet. Use of a
drill depth stop will provide additional
protection.
In general, body component replacement can be
accomplished with a minimum of specialized tools.
Most body components are held in place with
conventional removable hardware (nuts, bolts, washers
and screws). Some components are mounted with 'pop'
rivets which require that the rivet head be removed in
order to push out the shank of the rivet. The rivet head is
easily removed by drilling into the head with a sharp drill
bit that is slightly larger than the shank of the rivet (Ref
Fig. 1 on page C- 1). Care must be exercised when
drilling to prevent the drill from being forced through
and damaging components where it could damage
components located immediately behind the rivet. The
best way to prevent this from occurring is to use a sharp
drill bit that requires very little pressure to cut
successfully and to place a piece of protective sheet
metal between the surface being drilled and components
directly behind it.

BODY COMPONENT REPLACEMENT

The body components can be replaced by removing the
securing hardware, replacing the component and
securing with hardware in the same orientation as
removed. The illustrations on the following pages
indicate the assembly methods for the various
components.
If the instrument panel is to be replaced, the serial number
plate and CE plate must be removed and reinstalled on the
new instrument panel ( Refer Page C-2 ).
Repair and Service Manual
Pop Rivet
Fig. 1 Drill Out Metal Rivet
BODY
B
B
Drill out rivet
head only
Page C-1