On Sat, 10 Oct 2009 10:11:16 -0700, Jim Thompson
wrote:

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

What lubricant are you using? And is the tap sharp?