Dave wrote:

Another solution - especially with metric - is to tap the holes ( only bad - or all - so that they all match) to the next larger Metric size - of the same thread pitch as original - so as not to cut across the original threads, but just cut the same thread pitch to the next size, such as from 5mm to 5.5mm or 6mm. Then you only have to buy a standard - not too expesive - metric tap - and some new slightly larger hardware.

Unfortunately, 5 mm is the only standard metric thread with a 0.8 mm pitch, so you'd need a custom tap and would need to make custom bolts. Hence, my suggestion to just make some custom bolts in "M5.2x0.8" or "M5.5x0.8," whatever is necessary to get a tight fit. Same approach, but less work (although if someone ever loses the bolts, they'll go crazy trying to figure out what to use for replacements).

What I didn't mention previously, but would be good practice if you went that way, is to cut one straight flute on the bolts (look at a self-tapping machine screw to get the idea) to make it easier for them to deepen the major diameter of the original 5 mm thread.

Best regards,

Charles





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