Commonly used Drill bits, taps, and measurements

[cardcollector]

Hey all,

I decided that since I was compiling a list of common measurements I used, I thought it would make a great thread to have various drill bit used for switches, taps, etc...

So here is what I have so far. If you would like a measurement, post it up.

Drill bits, taps, and screws
For the Basic Switch
- Use a 3/8” bit for hole
- Or use a 1/2” bit for countersink

For the Lighted 16mm anti-Vandal Switch
-To tap and thread; 15mm bit w/ M16-1 tap
-Use a 23/32 endmill to countersink the AV switch. Drill a 5/8" hole first.

For the Gaurded Switch
- If you want to use the retaining nut; 1/2" bit
- For a force fit; 7/16” bit. 11.5mm bits work well also.

For the Small Momentary Switch
- To tap and thread; M5x0.5 tap with a 4.5mm bit

2.1mm Recharge Port
- To tap and thread; 5/16-32 tap (M8x.75 metric tap) & 9/32” dill bit

For the 5mm LED bezel
- To tap and thread; M8x0.75 metric tap & 7.25mm Drill bit. 5/16-32 tap is not compatible with the Bezel

For the T1 LED Indicators
-To tap and thread; M6 x0.75 metric tap & 5.25mm Drill bit

For R.I.C.E. Port Style #1
-To tap and thread; M6x0.5 metric tap & 5.5mm bit

For R.I.C.E. Port Style #1
-To tap and thread; M8x0.75 metric tap & 7.25mm Drill bit. 5/16-32 tap is not compatible.

Silver Tactile switch
-To snugly mount, use a 13/64" bit.




For 4-40 screws
- 4-40 tap with a 3/32" bit OR #43 drill bit

For 6-32 screws
- 6-32 tap with a 7/64" bit OR #36 drill bit

For 8-32 screws
- 8-32 tap and 9/64" bit OR #29 drill bit

For 10-32 screws
- 10-32 tap and 5/32" bit OR # 21 drill bit

Allen wrench Sizes
Hex size for socket head cap screws:
#2 - 5/64"
#4 - 3/32"
#6 - 7/64"
#8 - 9/64"
#10 - 5/32"
#12 - 5/32"

Hex size for button head cap screws:
#2 - .05"
#4 - 1/16"
#6 - 5/64"
#8 - 3/32"
#10 - 1/8"
#12 - 5/32"

Hex size for set screws:
#2 - .035"
#4 - 05"
#6 - 1/16"
#8 - 5/64"
#10 - 3/32"

Use as a guideline only.


Here are some measurements...

1.5” 22 gauge sinktube
-OD- 1.5”
-ID- 1.45”

1.25” 22 gauge sinktube
-OD- 1.25”
-ID- 1.20”

MHS Main body/double female connector/MHS to 1.5" adapter
- OD- 1.45"
- ID- 1.25"

Useful charts for taps and drill bits

Metric http://www.engineersedge.com/manufac...rill-chart.htm

ANSI http://www.engineersedge.com/tap_drill_chart.htm


I know this is by no means complete, so feel free to add to the list!

[Crystal Chambers]

Good idea. I would love to be more helpful but I don't have access to any saber stuff during the weekdays.

Can't forget our good friends in the blade retention/screw department.
8-32 tap, 9/64 bit

MHS mainbody/double female connector/ MHS to 1.5 sinktube adapter
1.45" OD
1.25" ID
(not sure how accurate this is but it's a must)


The other common screw sizes would be a nice addition too.
4-40, 6-32, 10-32

Accent LED holders would be the last common thing I can think of.

[Nineteen]

Another useful note would be which allen wrenches go with what screws. I know I often forget, and need to ask someone.

[cardcollector]

Added crystal.

Keep them coming!

[Shadar Al'Niende]

*votes for sticky*

[acerocket]

For 6-32 tap. drill size should be #36.

Hex size for socket head cap screws:
#2 - 5/64"
#4 - 3/32"
#6 - 7/64"
#8 - 9/64"
#10 - 5/32"
#12 - 5/32"

Hex size for button head cap screws:
#2 - .05"
#4 - 1/16"
#6 - 5/64"
#8 - 3/32"
#10 - 1/8"
#12 - 5/32"

Hex size for set screws:
#2 - .035"
#4 - 05"
#6 - 1/16"
#8 - 5/64"
#10 - 3/32"

These hex key sizes were pulled from a screw catalog I have and I have not taken the time to physically verify every one is correct. Use as a guideline only.


The 'correct' tap size for the recharge port is M8x.75 This is a metric tap. and it's Imperial equivalant is .315 - 33.87 - so it is very close to a 5/16 - 32.

On the 5mm LED bezels, I know the tap size for the cone shaped bezel is also M8x.75. I have not had the opportunity to purchase a low profile domed bezel yet to verify it's thread but I suspect it is also M8x.75.

Interestingly, the nuts that come on the 5mm cone type LED bezel and the 2.1mm recharge ports are interchangeable. However the LED bezel will not screw into a 5/16-32 threaded hole but the recharge port will. It probably has to do with the way they are manufactured and how loose the tolerances are.

[Rhyen Skytracker]

Here is the sizes needed for the T1 LED indicators http://www.thecustomsabershop.com/Gr...tor--P495.aspx

Tap M6 x .75 metric
Drill bit 5.25 mm

Also, the drill bit needed for the M8 x .75 that acerocket mentioned above is a 7.25mm bit.

[FenderBender]

Also, the force fit on the guarded switches work better with a 11.5mm bit/end mill

To counter sink an anti-vandal 23/32 end mill with 5/8 hole.

[Rhyen Skytracker]

Here are some drill and tap charts that I use:

Metric http://www.engineersedge.com/manufac...rill-chart.htm

ANSI http://www.engineersedge.com/tap_drill_chart.htm

This is turning out to be a very helpful thread and I think it should be a sticky thread.

[Onli-Won Kanomi]

This is an awesome and USEFUL thread to have this all in one place.

*seconds the suggestion for a 'sticky' on this*