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Below is a comprehensive drill and tap size chart for all drills and taps: Inch, imperial, and metric, ... 1 5.8000 0.22835 5.9000 0.23228 5.9436 0.23400 A
where is the tap drill size, is the major diameter of the tap (e.g., 10 mm for a M10×1.5 tap), and pitch is the pitch of the thread (1.5 mm in the case of a standard M10 tap) and so the correct drill size is 8.5 mm. This works for both fine and coarse pitches, and also produces an approximate 75% thread.
To calculate the major diameter of "aught" size screws count the number of extra zeroes and multiply this number by 0.013 in and subtract from 0.060 in. For example, the major diameter of a #0000 screw is 0.060 in − (3 × 0.013 in) = 0.060 in − 0.039 in = 0.021 in.
The correct tool to start a traditionally drilled hole (a hole drilled by a high-speed steel (HSS) twist drill bit) is a spotting drill bit (or a spot drill bit, as they are referenced in the U.S.). The included angle of the spotting drill bit should be the same as, or greater than, the conventional drill bit so that the drill bit will then ...
Because only 5 ⁄ 8 of this height is cut, the difference between major and minor diameters is 5 ⁄ 4 × 0.8660 × P = 1.0825 × P, so the tap drill size can be approximated by subtracting the thread pitch from the major diameter.
One aspect of this method of sizing is that the size increment between drill bits becomes larger as bit sizes get smaller: 100% for the step from 1/64 to 1/32, but a much smaller percentage between 1 47/64 and 1 3/4. Drill bit sizes are written as irreducible fractions. So, instead of 78/64 inch, or 1 14/64 inch, the size is noted as 1 7/32 inch.