Method for repairing self-piercing riveted workpieces

1. A method for repairing a self-piercing riveted workpiece having a discrepant joint caused by an improperly-installed-self-piercing rivet, the method comprising the steps of:

providing a repair rivet;

positioning the repair rivet proximate the discrepant joint such that the repair rivet is substantially aligned with the improperly-installed-self-piercing rivet; and

installing the repair rivet at substantially a same location on the workpiece as the improperly-installed-self-piercing rivet without removing the improperly-installed-self-piercing rivet and such that an end portion of the repair rivet directly engages an internal portion of the work piece.

2. The method of claim 1 , further comprising the step of positioning the repair rivet adjacent the discrepant joint and substantially centered over the improperly-installed-self-piercing rivet.

3. The method of claim 1 , further comprising the step of applying a sealant between the workpiece and the repair rivet.

4. The method of claim 1 , wherein the positioning step includes centering the repair rivet over the improperly-installed-self-piercing rivet.

5. A method for repairing a self-piercing riveted workpiece having a discrepant joint caused by an improperly-installed-self-piercing rivet, the method comprising the steps of:

providing a blind rivet assembly including a blind rivet and a mandrel extending through the blind rivet;

drilling through the improperly-installed-self-piercing rivet to form a hole;

inserting the blind rivet assembly into the hole; and

pulling the mandrel to create an upset portion of the blind rivet that engages the improperly-installed-self-piercing rivet and that further directly engages an internal portion of the work piece.

6. The method of claim 5 , further comprising the steps of providing a sealant and positioning the sealant between the blind rivet and the workpiece.

7. The method of claim 6 , further comprising the step of curing the sealant.

8. The method of claim 5 , wherein the drilling step comprises drilling through an approximate center of the improperly-installed-self-piercing rivet.

9. The method of claim 5 , further comprising the step of severing an end of the mandrel.

10. The method of claim 9 , wherein the severing step comprises severing the end such that a remaining portion of the mandrel is substantially flush with an upper end of the blind rivet.

11. The method of claim 5 , further comprising the steps of providing an sealant, positioning the sealant between the blind rivet and the workpiece, and curing the sealant, wherein the drilling step includes drilling through a portion of the workpiece, wherein the blind rivet has a length sufficient to extend beyond an end of the improperly-installed-self-piercing rivet when the blind rivet is inserted into the hole, and wherein the pulling step causes the upset portion to engage the workpiece.

12. The method of claim 11 , further comprising the step of severing an end portion of the mandrel.

13. The method of claim 12 , wherein the severing step comprises severing the end of the mandrel such that a remaining portion of the mandrel is substantially flush with an upper end of the blind rivet.

14. A method for repairing a self-piercing riveted workpiece having a discrepant joint caused by an improperly-installed-self-piercing rivet, the method comprising the steps of:

providing a self-piercing rivet;

positioning the self-piercing rivet at the discrepant joint at a first side of the workpiece opposite a second side of the workpiece where the improperly-installed-self-piercing rivet was installed;

placing a die over the improperly-installed-self-piercing rivet;

driving the self-piercing rivet into the first side of the workpiece to create an upset portion that engages the workpiece and that substantially surrounds an embedded end of the improperly-installed-self-piercing rivet.

15. The method of claim 14 , wherein the self-piercing rivet has a head and a protrusion under the head, and wherein the driving step comprises driving the self-piercing rivet into the first side of the workpiece until the protrusion is disposed below the first side of the workpiece.

16. The method of claim 15 , wherein the positioning step comprises positioning the self-piercing rivet such that the protrusion is substantially aligned with the embedded end of the improperly-installed-self-piercing rivet.

17. The method of claim 15 , wherein the driving step comprises driving the self-piercing rivet into the workpiece until an underside of the head is substantially flush with the first side of the workpiece.

18. The method of claim 17 , wherein the positioning step comprises positioning the self-piercing rivet such that the protrusion is substantially aligned with the embedded end of the improperly-installed-self-piercing rivet.