Hello, Martin:
Sorry to delay answering your question. . . I've been shooting like
mad and am swamped with post-processing.
There are two drill sizes associated with any machine screw; the
clearance drill, which creates a hole that will allow the screw
threads to pass through easily but still provide a good bearing
surfact for the screw head, and the tap drill, which creates a hole
somewhat smaller than the outside diameter of the threads and allows a
tap to be used to create threads on the inside of the hole. The screw
can then be repeatedly removed and reinserted into the threaded hole.
For a 6-32 machine screw, the clearance drill is 0.144" in diameter,
a number 27. (You don't need this size. . . it's for use when you are
using a nut and washer combination to fasten two objects together.)
The Tap drill is between 0.107" to 0.113"  depending on the hardness
of the material. For plastics, I suggest a number 36 drill ( 0.1065"
diameter.)
These drills are available at most hardware stores In a pinch, you can
use a 7/64" drill but I suggest the No. 36.
Just buy a number 36 drill, a  6-32 NC tap and a small tap wrench.
You can probably find  a tap wrench at a garage sale or an auction or
a flea market for a dollar or so. New ones are about $5-$10.  Same
goes for the tap although new 6-32 taps are about $3 - $4.
Email me if you have any problems.
David in Ft. Lauderdale
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