Lew,

I've tapped a pair of 8/32 holes in the end of a 1/2" dia rod
so close to the edges that the thread telegraphed to the
surface and they held just great.
I didn't want the part being atached on the end to be able
to rotate. That is the reason for the thing. I had to turn
down the diameter of the heads to put the two screws in. :-)
...lew...

Stan makes a very good point about not abusing fasteners, but the fact
is, it does work for many such tasks. Maybe post-lathe, I will do a
little better job via pins, and I certainly would find a better way for
something that had to take real punishment.

Thread-forming taps are now on order. That will hopefully allow me to
stay at 4-40, which should get us started w/o a gratuitous redesign.

Thanks to all who replied!

Bill