Repairing Plated Throughholes and Vias on a PCB

Through-holes or vias can be damaged in either handling of the boards or through the improper removal of a through-hole device. This tutorial will guide you through the repair process. The tools you will need include the following:

Caliper (or drill guage template)
Flux
Cleaning solvent
Microscope
Knife
Drill
Eyelet kit
Wipes
Eyelet forming tools
Solder
Soldering Iron
Drill bits or ball mills
Hammer

The more complete kit for Throughhole repair can be found here.

Step 1: Find the Right Drill Bit Size

Use progressively larger drill bits until you get to the right size where the plated hole can be drilled out. It should be slightly larger than than the opening of the plated through hole.

Step 2: Drill Out the Hole

Drill out the hole using a hand drill. Make sure you drill perpendicular to the plan of the PCB.

Step 3: Use Drill Template Gauge to Size Eyelet OD

Using a drill template gauge, size the correct eyelet size OD. A selection of eyelets that I use is here.

Step 4: Confirm That You Have the Right Eyelet Size

Using the drill guage make sure you have the correct eyelet size.

Step 5: Roll Eylet Flange Using Swaging Tool and Hammer

Place flange side of Eyelet on Swaging tool. Make sure that the PCB is level. Use 90 degree pick to “roll” flange out uniformly. Flat set using a hammer.

Step 6: Connect the Trace to the Eyelet

Add liquid flux and solder the land to the replacement eyelet to make the electrical connection. Allow solder to “wick” up 75% of the side of the flange.