75% tap drill ≈ major − (1/TPI) = 0.250 − 0.050 = 0.200 in. Shops use a #7 (0.201 in) or 13/64 in (0.203 in) drill, about 5.1 mm. Normal clearance is 6.6 mm (17/64 in). Fine 1/4-28 uses a #3 drill (0.213 in).
Common metric tap drills: M3 tap drill size · M6 tap drill 5.0 mm · M8 tap drill size · M10 tap drill 8.5 mm · M12 tap drill 10.2 mm · M24 tap drill 21.0 mm.
Formula
Major Ø 6.35 mm
Pitch 1.27 mm
Tap drill 5.1 mm
Minor Ø 4.975 mm
1/4-20 UNC at a glance
Tap drill vs clearance hole
Tap this hole (then cut the thread): 5.1 mm. Bolt must pass (clearance): 7.1 mm normal. That is why “1/4-20 UNC drill size” can mean two different holes — this page lists both.
How we use this in the toolroom
Imported US fixtures still arrive 1/4-20. We keep a #7 drill marked for it so nobody grabs a 5.0 mm (that is M6) by habit.
Accurate Industries in Pune still looks these sizes up the same way: tap drill ≈ major − pitch, then a clearance hole for the bolt. AlwaysReach is that chart in the browser — our story.
Full metric and imperial lookup lives on the thread & tap drill calculator. After tapping, check a locational bore on the ISO tolerance calculator. Other pages: M8 × 1.25, M10 × 1.5, M12 × 1.75, M6 × 1, M16 × 2, M4 × 0.7, M5 × 0.8, M3 × 0.5, M20 × 2.5, M24 × 3, 5/16-18 UNC, 3/8-16 UNC, 1/2-13 UNC, UNC chart, UNF chart, BSW chart, UNEF chart, BSF chart.