wrote in message
oups.com...

I also thought about buying a 2.5mm die and just re-threading about a
millimeter of the shoulder, reducing its length. Does this sound
reasonable?


Shoulder screws used in die making are hardened. I'd assume the same is true
for the ones you're using. This would make using a die nearly impossible.
You could anneal your screws, but you'll change the their properties and
capabilities.

Shoulder screws are typically specified using the shoulder diameter. If you
have been asking for 2.5mm shoulder screws, you may have been asking for the
wrong thing. I'd assume the shoulder on a shoulder screw with a M2.5 thread
would be 3mm - that's what you should be asking for.

Can you use a washer under the shoulder screw's socket head to make up the
1mm? You'll probably end up taking a financial bath to get your hands on the
screws you're specifying so I'd recommend using the ones to which you have
easy access. Perhaps redesign the part if possible? Counterbore the
component into which the shoulder screw is threaded?

HTH.

Regards,

Robin