[TenGees]

Making a 'roller' for a roller stand the other day. I noticed the same issue, drilling a 1/4" hole and expecting it to turn on a 1/4" bolt. I could barely get the bolt in (without using a hammer). So I measured some bits to see if I could find an oversized one... all of them were undersize! I finally found a knurled punch that opened the hole a bit. I guess the knurling added a little width to 1/4" material it was made from???

 

[TenGees]

Paul, remember the old military saying- Don't force it, use a bigger hammer! The bolt can measure under the 0.250 at the body but when the threads are cut, they are slightly bigger than the stated diameter. Ran into this many times.

John, the bolts had a shoulder where I was expecting rotation... but I never measured them!