"Roger Shoaf" wrote in message
...
You are going the wrong way. Use a 4 or a 5. It you jump up to an 8 you
are compounding the head size problem and you are asking for trouble if
your
drill walks on the end of the channel.

If you want to use a #6 screw use the fine thread.

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I don't know what you are making, but perhaps you should consider a
fastening method other than screws for this purpose - MUST the end caps be
removable? if not, glue or a spot weld might be a superior solution - and
you can drill and pin as well with much less machining, and if you put the
pins at a slight angle, you can prevent the cap from pulling off, or if you
make them straight, you will be able to tap it off later if you must.
Locktite on the pins can make it quite permanent



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