Where the burr is, and what the sources name
| Burr | Tool named | Source |
|---|---|---|
| Hole edge | Bearing scraper, countersink, or a drill bit larger than the hole, rotated by hand | Handbook p. 4-15 |
| Hole edge | Metal countersink or file; burr remover or larger drill bit | Handbook p. 4-40 |
| Hole edge | Oversize drill or deburring tool | AC 43.13-1B par. 4-58 |
| Sheet edge or hole | Burring tool | Handbook p. 4-14 |
| Between sheets | Chip chaser | Handbook p. 4-21 |
| Edges, heavier work | Die grinder, 12,000 to 20,000 rpm | Handbook p. 4-14 |
Why every hole
"Burrs must be removed to allow rivets or bolts to fit snugly and to prevent scratching." Before any rivet is driven, the Handbook wants all holes lined up and "all shavings and burrs" removed.
Hand drilling makes it worse: the Handbook notes that burrs form "especially" with a hand drill, because it turns slowly and invites more pressure per revolution. Burrs caught between sheets are what the chip chaser is for: a flexible steel blade with a hooked end.
The rule extends past rivets. For Hi-Lok fasteners, the Handbook says to deburr the hole edge so the head seats fully.
How to choose
Hole tools, by size. Most listed hole deburrers are made per size: Texas in/out tools from 3/32" to 1/4", LAS's two-way tool in the same five sizes. Yardstore's #1 rosebud covers 5/32" to 3/8" holes, so it misses the 3/32" and 1/8" rivet holes on the drill chart.
Both faces. The in/out and two-way tools are listed as cutting both sides of a hole; LAS says in one pass, with a set screw for depth of cut.
By hand or in a drill. The Handbook says that if a drill bit or countersink is used to deburr, "it should be rotated by hand". It says nothing about purpose-made drill-driven deburrers such as LAS's two-way tool or the rosebud. We report both; we do not rule between them.
Edges. For sheet edges the listings offer swivel-blade tools such as the Noga set and a dovetail edge deburr tool. The Noga listing does not give the blade type.
Deburring tools, as listed
| Tool | For | Listed spec | Where |
|---|---|---|---|
| Texas in/out kit, 5 pieces | Holes | 3/32" to 1/4"; replaceable HSS double-action blade; 1/4" shank | US · Yardstore |
| Texas in/out 1/8" | Holes | Single size; same blade | US · Yardstore |
| Two-way deburring tool | Holes | Drill-driven; both sides in one pass; 3/32" to 1/4" | UK/EU · LAS |
| Rosebud #1, 100° | Holes | Drill chuck; holes 5/32" to 3/8" | US · Yardstore |
| Noga set, 10 blades | Edges | Handle plus 10 blades; 6-1/4" long | US · Yardstore |
| Edge deburr tool | Edges | Dovetail end, guard, plastic grip | US · Yardstore |
| Chip chaser set | Between sheets | 2-1/2" and 5-1/2" hooked blades | US · Yardstore |
As the sellers list them. Each name links to the page with its source.
Questions people actually ask
What is the best deburring tool for aluminum?
The FAA sources name the tools, not a brand: a larger drill bit or countersink turned by hand, a burr remover or deburring tool, a file, a chip chaser between sheets. We have not tested the listed ones, so we rank none.
Can I use a Scotch-Brite wheel to deburr aluminum?
Neither the FAA Handbook nor AC 43.13-1B describes deburring with an abrasive wheel. The Handbook mentions a Scotch-Brite hand pad only for removing fretting residue around a rivet before inspection (p. 4-93). We have no source to cite either way, so we do not recommend it.
Can I deburr a hole with a drill bit?
Yes: a bit larger than the hole, rotated by hand, per the Handbook. AC 43.13-1B also names an oversize drill.
Do I need to deburr between the sheets?
The Handbook wants all shavings and burrs removed before riveting, and describes the chip chaser for burrs lodged between sheets after drilling.
Limits of this guide
What the sources support, and no further.
- No depth figure. Neither FAA source says how much chamfer a deburred hole may have.
- Abrasives are out of scope. No source we cite covers deburring wheels.
- Hand or drill is unresolved. The Handbook's hand-rotation advice is about bits and countersinks; it does not address purpose-made drill-driven deburrers.
- No tool was tested.
Sources
- FAA-H-8083-31, AMT Handbook — Airframe, Volume 1, Chapter 4 — p. 4-14, die grinder and burring tool; p. 4-15, burrs and how to remove them; p. 4-21, chip chaser; p. 4-40, drilling rivet holes, burrs before riveting; p. 4-51, deburring for Hi-Lok fasteners; p. 4-93, abrasive pad for fretting residue.
- FAA AC 43.13-1B CHG 1, Chapter 4, ¶4-58 — par. 4-58, p. 4-25: "Deburr the hole with an oversize drill or deburring tool."
- Seller listings — tool specifications, via the linked product pages at Yardstore and LAS Aerospace.