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Drill Reference Chart - SendCutSend

Drill Reference Chart

Use the reference chart below to correctly size your holes for drills and hardware.

How to use this chart

Find your drill or hardware thread size. The recommended close/free fit will be the size of your hole. Use the free size for a looser fit and close for a tight fit.

If you are countersinking, the close/free fit sizes will apply to your minor diameter.

Imperial Drill Sizes

Screw/
Thread
Size		Thread
Size
Examples		Major
Diameter		Close/Free
Fit
44-40.112″.117″ – .129″
66-32.138″.144″ – .150″
88-32.164″.169″ – .177″
1010-32.190″.196″ – .201″
1/41/4-20, 1/4-28.250″.257″ – .266″
5/165/16-18, 5/16-24.313″.323″ – .332″
3/83/8-16, 3/8-24.375″.386″ – .397″
7/167/16-14,7/16-20, 7/16-28.438″.453″ – .469″
1/21/2-13, 1/2-20, 1/2-28.500″.516″ – .533″
9/169/16-12, 9/16-18.556″.578″ – .594″
5/85/8-11, 5/8-18, 5/8-24.625″.640″ – .659″
11/1611/16-18, 11/16-24.688″.703″ – .723″
3/43/4-10, 3/4-16, 3/4-20.750″.766″ – .795″
13/1613/16-16, 13/16-20.813″.828″ – .862″
7/87/8-9, 7/8-14, 7/8-20.875″.891″ – .925″
15/1615/16-16, 15/16-20.938″.953” – .990″
11-8, 1-121.000″1.016″ – 1.1065″

Imperial Drill Sizes

Screw/
Thread
Size		Thread
Size
Examples		Major
Diameter
(MM)		Close/Free
Fit
(MM)
44-402.8452.972 – 3.277
66-323.5053.658 – 3.810
88-324.1664.293 – 4.496
1010-324.8264.978 – 5.105
1/41/4-20, 1/4-286.3506.528 – 6.756
5/165/16-18, 5/16-247.9508.204 – 8.433
3/83/8-16, 3/8-249.5259.804 – 10.084
7/167/16-14,7/16-20, 7/16-2811.11311.506 – 11.913
1/21/2-13, 1/2-20, 1/2-2812.70013.106 – 13.538
9/169/16-12, 9/16-1814.12914.684 – 15.083
5/85/8-11, 5/8-18, 5/8-2415.87516.256 – 16.739
11/1611/16-18, 11/16-2417.46317.859 – 18.364
3/43/4-10, 3/4-16, 3/4-2019.05019.446 – 20.193
13/1613/16-16, 13/16-2020.63821.034 – 21.895
7/87/8-9, 7/8-14, 7/8-2022.22522.621 – 23.495
15/1615/16-16, 15/16-2023.81324.209 – 25.146
11-8, 1-1225.40025.796 – 27.051

Additional Charts and Guidelines

Hardware Catalog

Min/Max Part Sizes

Service File Guidelines

Processing Min/Max Part Sizes

Hardware insertion and hole features

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We proudly use hardware by PEM

Flush stud, M8 x 1.25, .472" Zinc plus Clear Chromate

Aluminum: 5052, 6061, 7075 Steel: Mild

SKU FH-M8-12
Thread Size M8 x 1.25
Hole size in sheet (+0.003/-.0.000) .315″
Minimum sheet thickness 0.094″
Maximum sheet thickness .347″
Fastener material Steel
Minimum distance hole C/L to edge 0.378″
Minimum distance between two of the same hardware (CL to CL) .567″
Recommended panel material Steel/Aluminum
Coating type Zinc
Length .472″
Aluminum material ranges (5052, 6061, 7075) 0.100″-0.250″
Steel material ranges (CRS, HRPO, HR) 0.104″-0.250″

Get an Instant Quote for Waterjet Cutting

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  • Text should be converted to object and bridged where needed
  • All holes and cutouts should be at least 50% material thickness and no less than 0.070”
  • Bridging and webbing chould be at least 1:1 to material thickness
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We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Zinc plus Clear Chromate

Aluminum: 5052, 6061, 7075 Steel: Mild, G30

SKU SO-440-8
Thread Size 4-40 x .250″
Hole size in sheet (+0.003/-.0.000) .168″
Minimum sheet thickness 0.040″
Maximum sheet thickness .125″
Fastener material Steel
Minimum distance hole C/L to edge 0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole. .345″
Recommended panel material Steel/Aluminum
Coating type Zinc
Length .250″
Aluminum material ranges (5052, 6061, 7075) 0.040″-0.125″
Steel material ranges (CRS, HRPO, HR) 0.048″-0.119″

We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Passivated

Stainless Steel: 304, 316

SKU SO4-440-8
Thread Size 440
Hole size in sheet (+0.003/-.0.000) .166″
Minimum sheet thickness 0.04″
Maximum sheet thickness .125″
Fastener material 400 Stainless Steel
Minimum distance hole C/L to edge 0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole. Example shown with x2 of the same hardware. .313″
Recommended panel material Stainless Steel
Coating type Passivated
Length .250″
304 Stainless Steel material ranges 0.048″-0.125″
316 Stainless Steel material ranges 0.060″-0.125″