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Any thoughts? The drill will wander if I try the standard way

The easiest solution is to get a small punch and use a hammer with the punch to drive the rivet stem down below the rivet head. If the rivet pulled through the material the ball at the end of the rivet stem may allow the protruding bit to swivel - so be careful as you tap with the hammer. Try to strike the stem straight on (perpendicular to the rivet head).

Enjoy,

—Noel

If it's on a "delicate" surface that might deform with hammer taps, I found it's easy to cut an "X" right in the center of the stem with an ablative wheel on the Dremel. Takes the stem down a bit, and gives the drill bit a guide. Head of the rivet will protect the surface. Obviously, just a touch.

Thanks
Sort of a similar technique i tried is to use a clamp to squeeze the stem down. Having multiple methods in the quiver is a good thing to have though. Appreciate the advice.

I just used Noel's technique. The punch can be as large as the rivet to get it flush. Then use an old mandrel to punch it out completely. If you can have someone hold a bucking bar on the back makes it super easy. Bucking bar not required if there is thick structural stuff in the stack.

A light duty automatic center punch will give a quick sharp rap on the mandrel stem, much less likely to result in denting the aluminum surface than plain punch with hammer. May take a couple of knocks to dislodge the mandrel stem.

David A.

The one plus of a large punch to get the stem flush is actually two plusses. First, the punch doesn't tend to slip off the mandrel. Second, the rivet head protects the aluminum as the wide face doesn't tend to slip off the rivet. Of course you can hit it hard enough to dent it with the rivet head.

I knocked out countless proud mandrels in the leading edges. A pin punch worked a treat, sharp light whacks, not big heavy thuds, using electricians pliers as the hammer.

I've never tried the automatic centre punch, but it sounds like a good idea.

I've used a dremel with a carbide tip to grind the mandrel down till the drill will center.