Originally Posted by NovaTRON
I found rivet removal fairly easy: used an air hammer with sharpened chisel bit from the inside to shave off backs of the rivets. After, use the punch bit to pop out them out from the inside. Only took a few seconds per rivet. I found this was faster /easier than drilling all the holes in the sheets.
For any screws that are stripped out, i figured out that cutting a groove with a cutoff disc (on an angle grinder) into the head of the screw, then use a flat tipped screwdriver bit will easily removed any blown-out screw... If i had figured this 'trick' out sooner, I could have saved myself days.
An appropriate sized Roberts will usually work on phillips head screws where the driver slips the slot.
BTW, I read a long time ago that the phillips head was designed to slip to prevent stripping out the threads. That explains a lot.