Originally Posted by
BigChief
It can be tricky setting drive screws by hand. The body of the screw is supposed to be .001 to .002 over the size of the hole, so it has to be a perfect match. I think .002" might be a bit too tight for the harder steel used in bike frames. You would need a concave ended punch or the head of the drive screw will flatten. Then it's a 4 handed operation trying to line everything up and drive in the screw. I think you would be better off using a screw and tapped hole with lock tight or a rivet that clinches on the inside of the head tube.
Yeah, I bought some from McMaster Carr, drilled to their spec, and when I tried to tap the screws in, I could see the head tube was starting to deform. I bailed and just stuck the badge on with silicone and glued on dummy brass heads.