Lots of good tips on drilling out the rivets...
When it comes time to put it all back together..Get a second pair of hands..
It will save you lots of aggravation...

 

Everyone has already talked about the drill bits and how to remove the old hinge.

One more thing I found is after the installation. The screws were tightened to the amount needed as in the instructions. But after 6 months, the vibration cased two of the screws to back out.
I took Blue Locktite and have had no more problems. (I did it to all of the screws)

 

The first hinges I replaced, I used a drill, but the second for the second set I used a dremel with a steel grinding bit. (not the stone bits) to remove the rivets. Much easier.

 

I held the seal back with a putty knife and drilled the rivets from the inside. The dimple on that end of the rivet hold the drill bit in place.

 

Park the bike next to your wifes expedition/suburban and use the carpeted *** end of the suv as a work surface. She'll never know.

 

Have the dealer do it. No stress, no worry. So you have to pay for the labor-it's worth it!!

 

tombeving:
Do you use the drummel on the outside or inside of the pak and what happens to the remainder of the rivet? Does it pull out or do you have to punch it out?
Thanks again for your information

 

Not tombeving but...INSIDE, and yes, the rest will just fall out of you can pull it out.

 

Did mine this week and followed most of the tips here.

a couple of things I found........

follow the instructions and remove the hinge pin from the strap hinges and separate the top and bottom. I placed the top on a heavy quilt on a work bench.

I used a very sharp 5/32 bit and variable speed drill motor to slowly drill the rivets out of the bottom first from the inside. Go nice and slow and don't use too much pressure. They drill out pretty easy. I also held the hinge and the inside plates together to keep them from spinning using a pair of long nose vice grips (may be over kill but I am cautious).

Have someone hold the top while you slowly drill out the rivets. I used duct tape and my fingers to hold the weather seal out of the way.

After drilling.... remove the hinges then go back with a 3/16 bill to drill out the holes so the bolts and the studs for the top will fit through properly.

Definitely need at least 1 helper to hold the top while you install the screws.

I used red locktite to help keep them from vibrating out.

Overall easy job....intimidating but take your time and anyone can do it. Definitely worth the work as they look 10X better.

 

I did mine yesterday and they look AWESOME !!

I used my Dremel with a "Cut Off Wheel". I just ground the heads of the Rivets off. No drill required, just one to enlarge the holes in the TP some