Window Hinge Rivet Removal (UPVC Friction Stays)

Handles & Hinges UPVC Maintenance Ltd is a UK specialist in replacement parts for UPVC windows and doors. This guide explains how to remove old rivets from UPVC window hinges (friction stays) and refit the hinge using either new rivets or screws.

Tools & materials

• Hand drill or cordless driver
• Drill bits: 3 mm pilot, then 4–5 mm to remove rivet heads
• Centre punch or sharp nail (for accuracy)
• Flat screwdriver or thin pry tool
• Masking tape or card shim (to protect frame)
• Refit with: stainless pop rivets (4.0–4.8 mm) or stainless screws with washers & nyloc nuts
• Hand riveter (if using pop rivets)

Step-by-step

1. Support the sash
   Open the window and support the sash so it can’t drop or twist when the hinge is released. Use a helper or a sash prop.
2. Protect the work area
   Apply masking tape around the rivet head and slide a card or thin plastic behind the hinge to prevent accidental damage.
3. Centre and pilot
   Mark the middle of the rivet head with a centre punch. Drill a 3 mm pilot hole to guide the next drill size.
4. Drill off the rivet head
   Step up to a 4–5 mm bit and drill slowly until the rivet head detaches. Stop once it spins or comes free.
5. Remove head and shank
   Pry the loose head away with a screwdriver, then push the remaining shank through the hole with a punch.
6. Remove the hinge
   Once all rivets are out, lift the hinge away from the sash and frame. Clean any debris from the channel or Eurogroove.
7. Refit with new fasteners
   Position the new (or serviced) hinge. Either pop-rivet it back using the correct diameter/length or use stainless screws with washers and nyloc nuts. Tighten securely but don’t overtighten.

Tips for success

• Use sharp drill bits for a clean cut and less wandering.
• Support the sash throughout to prevent misalignment or hinge strain.
• Replace rivets or screws like-for-like in size and material for best durability.