I made my own from office Binder clips( 3/4" X 3/8" size). An elder Bassmaster at AI(MD) showed me this trick. If I knew his name I would certainly give him the credit.
Recommended hole size for a 4-40 thread rolling screw for 70% thread engagement into steel is .1006" (#39 or # 38 drill).
Pilot hole sizes for thread forming srews tend to be a little larger than pilot holes for self-tapping screws.
If you indeed have a self-tapping screw, then I would recommend starting with a pilot hole near .096" (i.e # 41 drill).
You can also, use a 6/32 screw uses a #36 bit for regular threads, and a # 35 or 34 for self tapping screws . Use only blunt tip screws for construction.
Try it , fantastic little Idea, that is CHEAP to make and implement!
[This message was edited by AI4WD on 11-24-03 at 12:00 PM.]