#5-40 Tap Drill Size
The tap drill for #5-40 UNC is #38 (0.1015 in, 2.58 mm). That is the standard chart size and leaves about 72% thread.
Drill a #38 hole, then cut the thread with a #5-40 tap. The hole is 0.0235 in narrower than the screw, so the tap cuts 0.0117 in into each side.
A full-height thread would be 0.0162 in deep on each side. The #38 drill leaves 72% of that.
Try another material or drill
#5-40 tap drill size by material
| Material | Target thread | Drill | Size | Thread left |
|---|---|---|---|---|
| Aluminum, brass, plastics | 75% | #38 | 0.1015 in (2.58 mm) | 72% |
| Mild steel | 60% | #37 | 0.1040 in (2.64 mm) | 65% |
| Stainless, titanium | 50% | 7/64 in | 0.1094 in (2.78 mm) | 48% |
The 75% row is the published chart drill. The 60% and 50% rows pick the biggest standard drill that still leaves close to that much thread.
Notes on #5-40
#38 is the chart drill for #5-40 and leaves 72%. Steel takes #37 (65%) and stainless takes 7/64 in (48%).
#5 is 0.1250 in (3.17 mm) across, close to M3 at 0.17 mm away. Its pitch is 0.50 mm against 0.635 mm here.
How much thread do you need?
The chart prints one drill. The right amount of thread depends on the material, and the guides give slightly different ranges.
| Material | Texas Metalworks | ToolGrit | OSG (tap maker) | Drill for #5-40 |
|---|---|---|---|---|
| Aluminum | 70-75% | 60-65% | 65-70% | #38 (72%) to #37 (65%) |
| Brass | 70-75% | 70-75% | 65-70% | #38 (72%) |
| Plastic | not covered | 70-75% | not covered | #38 (72%) |
| Mild steel | 60-65% | 60-65% | 65-70% | #37 (65%) |
| Stainless steel | 50% | 55-60% | 60-70% | #37 (65%) to 7/64 in (48%) |
| Titanium | 50% | 50-55% | not covered | 7/64 in (48%) |
The three rows in the first table follow Texas Metalworks. OSG makes taps, and asks for more thread in stainless than either guide, so its range sits closer to our steel column. ToolGrit also suggests 50 to 55% for blind holes in stainless, titanium and hardened steel, and for small taps (#6 and below), which includes #5-40.
Why not a full thread?
A 100% thread is not possible in practice. The tap and the thread both have flat crests and roots (ToolGrit).
More thread also means more work for the tap: higher cutting force, more heat, poorer chip clearance and a bigger risk of breaking it (ToolGrit).
And it adds little strength. ToolGrit cites studies showing about 90% of a thread's shear strength at 60% thread. Texas Metalworks says going from 75% to 60% costs only about 5% of pull-out strength.
On #5-40, that step is from #38 to #37. The two drills differ by 0.0025 in.
If you do not have the #38 drill
Here are the drills on either side, and the thread each one leaves.
| Drill | Size | Thread left | What changes |
|---|---|---|---|
| #40 | 0.0980 in (2.49 mm) | 83% | More thread, harder to tap |
| #39 | 0.0995 in (2.53 mm) | 79% | More thread, harder to tap |
| #38 | 0.1015 in (2.58 mm) | 72% | Standard size |
| #37 | 0.1040 in (2.64 mm) | 65% | Less thread, easier to tap |
| #36 | 0.1065 in (2.71 mm) | 57% | Less thread, easier to tap |
A bigger drill removes thread and makes the tap easier to turn. A smaller drill keeps more thread and puts more torque on the tap.
The check behind the #38 number: (0.1250 - 0.1015) / (1.299 x 0.0250) = 72.4%.
What #5-40 means
- #5
- A screw gauge number. The major diameter is 0.060 + 0.013 x 5 = 0.1250 in (3.17 mm).
- 40
- Threads per inch, so one thread every 0.0250 in (0.635 mm).
- UNC
- Unified National Coarse.
The rest of the size, worked out from the major diameter and pitch:
| Property | Value |
|---|---|
| Major diameter | 0.1250 in (3.17 mm) |
| Pitch | 40 TPI (0.635 mm) |
| Pitch diameter (basic) | 0.1088 in (2.76 mm) |
| Minor diameter, internal thread (basic) | 0.0979 in (2.49 mm) |
The pitch and minor diameters are for checking a thread with gauges. You can skip them if you only need the drill.
How long to make the #5-40 thread
Aim for a thread at least 1 to 1.5 times the diameter long. ToolGrit's strength figures assume that length.
| Thread length | In threads | Drill a blind hole at least |
|---|---|---|
| 1 x diameter: 0.125 in | 5 | 0.225 in |
| 1.5 x diameter: 0.188 in | 7.5 | 0.287 in |
The blind hole depth adds 4 threads (4 x 0.0250 in) so the tap has room to finish and the chips have somewhere to go.
How to tap a #5-40 hole
- Drill the hole with the #38 drill (0.1015 in, 2.58 mm).
- For a blind hole, drill 0.225 in deep if you need a 0.125 in thread. That is 4 threads past the thread (ToolGrit).
- Put cutting fluid on the tap. Do not tap dry (ToolGrit, Wikipedia).
- Hold the tap in line with the hole.
- Turn the tap forward, then back it off now and then to break the chip (Wikipedia).
- Need threads right to the bottom of a blind hole? Finish with a bottoming tap (Wikipedia).
Taps usually break for one of these reasons (Wikipedia, ToolGrit):
- Chips clog the flutes.
- The tap is not in line with the hole.
- The tap is pushed too hard or too little.
- There is not enough cutting fluid.
- The drill was too small, so the tap works against too much thread.
Which tap to use for #5-40
The three common hand taps differ in how many threads at the tip are tapered (Wikipedia).
- Taper tap: 8 to 10 tapered threads, about 0.2000 in to 0.2500 in on #5-40. For hard materials and very small taps.
- Plug tap: 3 to 5 tapered threads, about 0.0750 in to 0.1250 in on #5-40. The most common tap, easy to start and keep straight.
- Bottoming tap: 1 to 1.5 tapered threads, about 0.0250 in to 0.0375 in on #5-40. Cuts threads to the bottom of a blind hole, usually after a plug tap.
Spiral-point taps are usually used in through holes so the chips can escape. Spiral-flute taps work well in blind holes (Wikipedia).
Forming (roll) taps only work in malleable metals such as mild steel and aluminum (Wikipedia). They use different drill sizes, which we do not cover yet.
Closest metric size
M3 is close to #5-40, but it is not the same thread.
| Major diameter | Pitch | Standard drill | |
|---|---|---|---|
| #5-40 | 3.17 mm | 0.635 mm | #38 |
| M3 | 3.00 mm | 0.500 mm | 2.5 mm |
The diameters differ by 0.17 mm and the pitches are not the same. Do not swap them.
FAQ
What is the tap drill size for #5-40?
The standard drill is #38 (0.1015 in, 2.58 mm). It leaves about 72% thread, which is the standard chart choice.
Can I use #37 instead of #38 for #5-40?
#37 (0.1040 in, 2.64 mm) leaves about 65% thread instead of 72%. The tap cuts more easily and the thread is weaker. That is still at or above the 60% Texas Metalworks suggests for mild steel.
Is a 2.6 mm drill the same as #38?
It is very close. 2.6 mm is 0.1024 in, against 0.1015 in, 2.58 mm for #38. It leaves about 70% thread.
What drill size do I use for #5-40 in aluminum?
Use #38 (72%) or #37 (65%), depending on the guide. Texas Metalworks says 70 to 75% for soft aluminum, which is #38. ToolGrit says 60 to 65% for aluminum alloys, which is #37. Either is a normal choice. OSG, a tap maker, gives 65 to 70% for average work in aluminum, brass and mild steel.
What is the tap drill size for #5-40 in stainless steel?
7/64 in (0.1094 in, 2.78 mm) leaves about 48% thread, close to the 50% Texas Metalworks recommends for stainless and titanium. ToolGrit gives 55 to 60% for 304 and 316 stainless, which is between #37 and 7/64 in. The standard drill, #38, puts more torque on the tap. OSG, a tap maker, asks for 60 to 70% in stainless for average work, which is closer to the steel drill, #37.
Does a bigger drill make the #5-40 thread much weaker?
Not by much at first. ToolGrit cites studies showing about 90% of a thread's shear strength at 60% thread, if the thread is at least 1 to 1.5 times the diameter long. Texas Metalworks says going from 75% to 60% costs only about 5% of pull-out strength. For #5-40, the 60% drill is #37.
How long should a #5-40 thread be?
Aim for at least 1 to 1.5 times the diameter, the length ToolGrit's strength figures assume. For #5-40 that is 0.125 in to 0.188 in, or about 5 to 7.5 threads.
How deep do I drill a blind #5-40 hole?
At least 4 threads deeper than the thread you need, says ToolGrit. A 0.125 in thread needs a hole at least 0.225 in deep.
Which tap do I use for a blind #5-40 hole?
Start with a plug tap, then finish with a bottoming tap if the thread has to reach the bottom. Wikipedia says a bottoming tap has 1 to 1.5 tapered threads, about 0.0250 in to 0.0375 in on #5-40.
What is #5-40 in mm?
#5-40 is 3.17 mm across, with a pitch of 0.635 mm.
Is #5-40 a coarse or fine thread?
#5-40 is a coarse thread (UNC).
Related sizes
Chart drill checked against the American Fastener tap and drill chart and the Fabworks tap drill chart. Diameters from Wikipedia: drill bit sizes. Thread percentages, thread length and blind-hole depth from Texas Metalworks and ToolGrit. The percentage formula is the one printed in the OSG tap drill chart, Vol 3 (2024). Tap types and tapping tips from Wikipedia. Last reviewed October 7, 2026.