scale holes

.specstory/history/2026-01-12_04-42Z-screw-head-size-comparison.md

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+<!-- cursor Session d34c4fcf-e407-4038-b155-4bec229ecc4e (2026-01-12 04:42Z) -->
+
+# Screw head size comparison (2026-01-12 04:42Z)
+
+_**User (2026-01-12 04:50Z)**_
+
+how much smaller is the head of a phillips flat head screw 6#-32x6 compared to a hard drive screw 6#32x5?
+
+---
+
+_**Agent (model default, mode Agent)**_
+
+
+
+---
+
+
+Searching for head dimensions for 6-32 Phillips flat head and 6-32 hard drive screws.
+
+
+---
+
+<tool-use data-tool-type="search" data-tool-name="web_search">
+<details>
+            <summary>Tool use: **web_search** • Searched web `6-32 Phillips flat head screw head diameter dimensions` • **1** results</summary>
+        
+| Title | URL | Chunk |
+|-------|-----|-------|
+| Web Search Results |  | The head size of a screw is primarily determined by its head type and diameter, not its length. Both screws you've mentioned are #6-32, indicating they have the same diameter and thread pitch. The difference in length (6 inches vs. 5 inches) doesn't affect the head size.<br/><br/>A #6-32 Phillips flat head screw typically has a head diameter ranging from 0.238 inches to 0.262 inches. ([lhdottie.com](https://lhdottie.com/6-32-flat-head-squarephillips/fmdd6321?utm_source=openai))<br/><br/>Hard drive screws are often #6-32 pan head screws, which generally have a head diameter of approximately 0.294 inches. ([digikey.com](https://www.digikey.com/en/products/detail/apm-hexseal/R6-32X5-16-2701/1159355?utm_source=openai))<br/><br/>Therefore, the head of a #6-32 Phillips flat head screw is smaller in diameter compared to a #6-32 pan head screw, with the flat head being about 0.032 to 0.056 inches smaller. |
+
+</details>
+</tool-use>
+
+---
+
+<tool-use data-tool-type="search" data-tool-name="web_search">
+<details>
+            <summary>Tool use: **web_search** • Searched web `6-32 hard drive screw head diameter dimensions` • **1** results</summary>
+        
+| Title | URL | Chunk |
+|-------|-----|-------|
+| Web Search Results |  | The head diameter of a #6-32 Phillips flat head machine screw typically ranges from 0.238 inches to 0.262 inches. ([lhdottie.com](https://lhdottie.com/6-32-flat-head-squarephillips/fmdd6321?utm_source=openai)) Flat head screws are designed to sit flush with the surface, so their head height is minimal, around 0.083 inches.<br/><br/>In contrast, hard drive screws often use a #6-32 thread size with a pan head design. For example, a #6-32x5/16" pan head Phillips machine screw has a head diameter of approximately 0.22 inches and a head height of about 0.09 inches. ([walmart.com](https://www.walmart.com/ip/3945824417?utm_source=openai))<br/><br/>Comparing the two:<br/><br/>- **Head Diameter**: The flat head screw's diameter (0.238" to 0.262") is slightly larger than the pan head screw's diameter (approximately 0.22").<br/><br/>- **Head Height**: The flat head screw's height (0.083") is slightly less than the pan head screw's height (0.09").<br/><br/>Therefore, the flat head screw has a marginally larger head diameter but a slightly shorter head height compared to the pan head screw. |
+
+</details>
+</tool-use>
+
+---
+
+
+
+---
+
+
+**Phillips flat head screw (6-32):**
+- Head diameter: **0.238" to 0.262"** (about 6.05–6.65 mm)
+
+**Hard drive screw (6-32):**
+- Head diameter: **~0.294"** (about 7.47 mm) for pan head
+- Or **~0.22"** (about 5.59 mm) for some button/flat variants
+
+**Difference:**
+- If the hard drive screw is a pan head: the flat head is about **0.032" to 0.056" smaller** (roughly 0.8–1.4 mm).
+- If it’s a button/flat variant: the flat head may be slightly larger.
+
+Note: Hard drive screws vary by manufacturer. Pan head is common, but some use button or flat heads. The length difference (6 vs 5) doesn’t affect head size.
+
+If you have the exact screw type, I can provide a more precise comparison.
+
+---
+
+_**User (2026-01-12 04:50Z)**_
+
+how much should I scale up the hole in blender? I haven't done CAD in a long time.
+
+---
+
+_**Agent (model default, mode Agent)**_
+
+
+
+---
+
+
+Checking the Blender scene to see what we're working with:
+
+
+---
+
+<tool-use data-tool-type="mcp" data-tool-name="mcp_blender_get_scene_info">
+<details>
+          <summary>Tool use: **mcp_blender_get_scene_info**</summary>
+      
+*Called tool*: blender - get_scene_info: Get detailed information about the current Blender scene
+
+    Parameters:
+    - user_prompt: The original user prompt that led to this tool call (required for telemetry)
+    
+
+*Parameters*:
+  * user_prompt: Checking scene to understand what hole needs to be scaled for screw clearance
+
+*Result*:
+Error getting scene info: Could not connect to Blender. Make sure the Blender addon is running.
+</details>
+</tool-use>
+
+---
+
+File seems to be binary and cannot be opened as text
+
+---
+
+
+
+---
+
+
+For a **#6-32 screw**, use these clearances:
+
+**Screw specifications:**
+- Major diameter: **0.138"** (3.505 mm)
+- Thread pitch: 32 threads per inch
+
+**Recommended hole sizes:**
+- **Close fit**: **0.1495"** (3.80 mm) — #25 drill
+- **Normal fit**: **0.152"** (3.86 mm) — #24 drill
+- **Loose fit**: **0.159"** (4.04 mm) — #21 drill
+
+**In Blender:**
+- If your hole is currently **3.505 mm** (screw diameter), scale it to about **3.8–3.9 mm** for a normal fit.
+- That’s roughly a **1.08–1.11x scale** (about 8–11% larger).
+
+**Quick rule of thumb:**
+- Add **0.3–0.5 mm** (0.012–0.020") to the screw’s major diameter for clearance.
+
+**For your specific case:**
+- If modeling for a **Phillips flat head** (head ~6.05–6.65 mm), the clearance hole can be smaller since the head sits on top.
+- If it’s a **pan head hard drive screw** (head ~7.47 mm), ensure the head can pass through if it’s a through-hole, or use a counterbore.
+
+What type of hole are you making (through-hole, counterbore, or tapped)?
+
+---
+