On Mar 2, 2014, at 12:55 PM, Crusty OMO <[email protected]> wrote:

> Now, what about the hole size?  42mil was the original size, I've reduced it 
> to 38... but I think that's going to be a mistake, I want to return it to 
> 42mil, thoughts?

For DIP components, I usually use 35 mil.  30 mil will do in a pinch, at least 
for standard DIP parts (especially if you're using machined-pin sockets, which 
you should all be using instead of the dual-wipe sockets for longevity and 
stability's sake).  35 mil will be a bit snug on header posts, which have a 
diagonal of 35.3 mil (it should still fit, but snugly; that's actually pretty 
useful for soldering, since it keeps them from moving when the plastic heats 
up).  38 mil should accommodate damn near anything except maybe really large 
leads from e.g. power transistors and rectifier diodes.

Also, for the sake of pedantry (because taxonomy is important), it's a DE9 
connector; DE specifies the size, 9 specifies the number of pins.  A DB9 
connector is the same size as a DB25, but would only have 9 pins stuffed.  The 
common 15-pin size (used for Mac monitors, PC game ports and others) is DA15.


- Dave


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