"Jim Thompson"
wrote in message ...
1/4"-20 tap calls for 0.201" tap drill (13/64")

Into a steel 1/8" panel, tap is hard enough to turn that handles flex
:-(

Is that normal, or do I need to go up one or more drill sizes?

...Jim Thompson

The 0.201 (13/64") is for softer materials. You want
to go to a 7/32" drill for harder materials. Also, you
have to decide if you want 75% or 50% threads.

I was in manufacturing for 25+ years.

Bill