Choosing The Right Screw Size: The Next Step Up

If you're looking for a screw size that's larger than 6-32, you have a few options. The next two larger sizes are 5-40 and 8-32, with 8-32 being the most common screw size for light fixtures. It's important to note that the numbers on screws, such as #6 or #8, refer to the diameter of the screw, with higher numbers indicating larger diameters. When selecting the right screw size, it's crucial to consider the specific application and any special requirements, such as load-bearing capacity and environmental conditions.

The next size down is 4-40, which is generally one size smaller

If you're looking for a smaller screw than a 6-32, then a 4-40 screw is generally one size down. This is a common screw size, so you'll have no trouble finding what you need.

A 4-40 screw has a diameter of 0.1120 inches (or 14/125 inches) and 40 threads per inch. To put that into context, a 6-32 screw has a diameter of 0.1380 inches (or 69/500 inches) and 32 threads per inch. So, as you can see, the 4-40 is a fair bit smaller.

You can get 4-40 screws in various lengths, and they are typically made from stainless steel, with a Phillips pan head. They are often sold in packs of 100 or more, and you can also buy matching nuts and washers.

If you need to go even smaller, the next size down from a 4-40 is a 2-56 screw, which has a diameter of 0.0860 inches (or 43/500 inches) and 56 threads per inch.

The previous answer may not apply to newer products, which are likely to be metric

Metric screws are designated with an 'M' followed by a number, which indicates the diameter of the screw in millimetres. So, an M4 screw has a diameter of 4 millimetres. The 'M' designation is followed by a number, which indicates the size of the screw. The larger the number, the larger the screw size.

Metric screws are commonly used outside of the USA and in products by global manufacturers such as HP. If you are in the US and have a product from a global manufacturer, it is likely that your screws will be metric.

If you are unsure whether your screws are metric or imperial, you can measure the diameter with a ruler. A 6-32 screw will have a diameter of exactly 3/16 inches, whereas an M3.5 screw will be slightly larger at approximately 0.228 inches (slightly more than 7/32 inches).

The 4-40 screw has a diameter of 0.1120 or 14/125 and 40 threads per inch

The 4-40 screw is generally considered one size smaller than the 6-32 screw. It has a diameter of 0.1120 inches, or 14/125 inches, and 40 threads per inch.

The 4-40 screw is a common size used in a variety of applications. Its diameter is slightly smaller than that of the 6-32 screw, which has a diameter of 0.1380 inches or 69/500 inches. The 4-40 screw's smaller diameter makes it suitable for use in applications where a smaller or thinner screw is required.

The number of threads per inch, or TPI, is another important factor to consider when choosing the correct screw size. The 4-40 screw has 40 threads per inch, which is a higher thread count compared to the 6-32 screw, which has 32 threads per inch. A higher thread count can provide a more secure hold in certain materials, so it is important to select the correct screw size and thread count for your specific application.

When selecting a screw, it is important to refer to a screw chart or guide to ensure you are choosing the correct size and type for your project. Screw charts can be confusing, but they provide valuable information about screw sizes, diameters, and thread counts. They can also help you identify the correct type of screw for your specific application, whether it be for wood, metal, or another material.

In addition to standard screw sizes, it is worth noting that screws can also be metric, especially if they are newer products or made outside of the US. Metric screws follow a different sizing system, so it is important to be aware of the differences when working with screws and fasteners.

The 6-32 screw has a diameter of 0.1380 or 69/500 and 32 threads per inch

The 6-32 screw is a standard SAE numeric system small machine screw. It has a basic diameter of 0.1380 inches, or 69/500 inches expressed as a fraction, and 32 threads per inch.

The 6-32 screw is larger than the 5-40 screw, which has a diameter of 0.1250 inches or 1/8 inches as a fraction, and 40 threads per inch. The 5-40 screw is one size smaller than the 6-32.

The two sizes smaller than a 6-32 screw are the 4-40 and 2-56 screws. The 4-40 screw has a diameter of 0.1120 inches or 14/125 inches as a fraction, and 40 threads per inch. The 2-56 screw is even smaller, with a diameter of 0.0860 inches or 43/500 inches as a fraction, and 56 threads per inch.

It's important to note that screws can also be metric, especially if they are newer or made outside of the US.

The next size up is likely to be 8-32, which is commonly used for light fixtures

If you're looking for the next screw size up from a 6-32, you're likely to be looking at an 8-32. This screw size is commonly used for light fixtures, and it's bigger than a 6-32 screw, as indicated by the larger first number, which refers to the screw's diameter.

The 8-32 screw is a versatile fastener with a wide range of applications. It's often used for securing machine parts, attaching hardware and brackets, fastening sheet metal, and joining wood to metal. These screws are also useful for installing cabinet hardware and securing decorative trim. With a pan head (a round head that sits flush against the surface) and a Phillips (star-shaped) recess, they are both functional and aesthetically pleasing.

The 8-32 designation refers to the screw's nominal diameter of 8mm and its thread count of 32 threads per inch. While the diameter may vary slightly depending on the brand, the thread count remains constant. These screws are typically made from stainless steel, which offers strength and durability, making them ideal for heavy-wear applications.

Phillips pan head machine screws, including the 8-32 variety, are known for their ease of use. The recessed design provides cam-out resistance, making them simple to install and remove. Additionally, they are relatively inexpensive compared to other screw types, and non-magnetic options are available for electronics and mechanics applications.

Frequently asked questions