I've seen somebody talk about fixing bad posts by using the slightly heavier pitch M2.5-0.40 screws to replace the original M2.5-0.35 (or is it -0.30) to repair various atomizers. I'll assume it was you. A few questions...
Do you get replacement screws in the original pitch but with heads more conducive to our needs, ie flat bottoms to trap wire better from Amazon also?
Do you tap the higher pitch in the post or just force in the screw?
You've mentioned going up a size when posts are badly mangled. I'm pretty sure you have to tap these. Again, did you get tap and screws from Amazon?
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I use standard Metric Taps: M1.6 x 0.35 , M2.0 x 0.40 , M2.5 x 0.45 and M3.0 x 0.5
When the post
threads are damaged, I just Tap them one size bigger (not pitch) M1.6 becomes M2.0, M2.0 becomes M2.5 and so on.
Before Tapping new
Threads, I drill the Posts to:
1. For M1.6 drill 1.45mm
2. For M2.0 drill 1.60mm
3. For M2.5 drill 2.05mm
4. For M3.0 drill 2.50mm
I only used two criteria to chose my replacement screws:
1. They absolutely, positively have to be made out of food/surgical grade Stainless Steel.
2. They have to have flat bottom heads.
The length of the screws seemed to be standard at 4.0 mm for all my replacement screws, even M1.6
kayfun has 4mm screws.
In some application I grind them shorter (Fogger Positive Posts) or re-shape the heads (Taifun GT and Fogger Top Cap filling modification)
But those were the same M2.5 screws that I got 100 of for $3.41 here:
http://www.amazon.com/gp/product/B000FN7Z5K/ref=oh_aui_detailpage_o01_s01?ie=UTF8&psc=1
M2.0 100 of for $4.80 here:
Stainless Steel Machine Screw, Plain Finish, Pan Head, Phillips Drive, 4mm Length, M2-0.4 Threads (Pack of 100): Amazon.com: Industrial & Scientific
And M1.6 10 of for $4.35 here:
18-8 Stainless Steel Machine Screw, Plain Finish, Cheese Head, Slotted Drive, Meets DIN 84, 4mm Length, Fully Threaded, M1.6-0.35 Metric Coarse Threads (Pack of 10): Amazon.com: Industrial & Scientific
The Drill Bits and the Taps (and Dies) I bought on eBay, Amazon and my local Tool Supply stores.
Just one thing to remember:
Stainless Steel in not Hard, but it is TUFF, therefore only the Good Quality drill bits and tsps. should be used.