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1/2-20 UNF Tap Drill Size

The number you came for, then the reasoning behind it.

1/2-20 UNF tap drill — 75% thread 29/64 0.4531" · 11.5 mm metric equivalent

How it's calculated

Tap drill = major diameter − (0.01299 × %thread) / TPI  →  0.5000 − (0.01299 × 75) / 20 = 0.4513"

The nearest standard drill above that is 29/64 at 0.4531".

All engagement percentages

% threadExact hole Inch drill Metric equivalent
50%0.4675"15/32 (0.4688")11.9 mm
65%0.4578"29/64 (0.4531")11.6 mm
75%0.4513"29/64 (0.4531")11.5 mm
85%0.4448"7/16 (0.4375")11.3 mm
Which percentage should you actually use?
75% for through-holes in mild steel and aluminium. 65% for blind holes, stainless, titanium and anything where the tap is at risk. 50% for hand-tapping deep holes. The strength you give up going from 75% to 60% is around 5%; the tapping torque you give up is around 30%. In practice the threads almost never fail — the tap does.

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