Machine Screws

http://www.google.co.uk/search?q=%238-32+x+3%2F8+Flat+Head+Machine+Screw&sourceid=ie7&rls=com.microsoft:en-gb:IE-SearchBox&ie=&oe=&redir_esc=&ei=yZzVS5XCNM2B_QaFvqmlDw

peterg7lyq, I appreciate the input but I've already done the whole "google search" thing to no avail. I'm now trying to reach outside the box and see if someone knows specific places that I should check out.

Well, that is an unusual request.

Here is a link to a datasheet, with all requirements met... sort of. Phillips drive size is #2... #1 drive not available until #4 shank. As you indicate, I believe a small run of custom screws would be expensive. If this particular requirement is important to your process, you might consider it simply a cost of doing business.

Is it impractical to change drivers for the process involved? Is it a good idea to assemble with a component that will be next to impossible for a subsequent user to replace correctly?

Thanks Doorman. I appreciate your suggestions, particularly regarding down line use. You're right about the web site. Yet another company that doesn't offer a #1 drive until you drop down to a #4-40.

You're welcome Casper85. Glad to be of limited help.

This thread is still pretty new... give it a while, someone may know of a manufactured item that hits all of your spec's.

Welcome to the discussion forum. Caution: It may be habit forming!

Is this a manufacturing requirement, or a product requirement? 

They don't meet your Ph #1 requirement, but I usually go here for hard to find parts:

http://www.mcmaster.com/#machine-screws/=6u4j6g

What is so sacred about #1 Phillips? are you trying to limit tightening torque?

I have a fairly extensive screw collection, and just checked several hundred assorted screws. All the #8 and #6 Philips heads were #2 Phillips.

Just accept that #2 is standard, and go with that! If you must use #1 to limit torque, or perhaps to make the driver fit through a limited entry, redesign the part with #4 screws.

Personally, I'd abandon Phillips for Hex or Torx - MUCH better for the repairman when the time comes... Unfortunately, very few devices are designed with repair in mind. From my point of view, any device that isn't designed to be repaired ought to have a stiff disposal surcharge.

Try here...we use them and they are not too expensive.

You haven't told us yet why you want #1 Phillips.

There's lots of people here who might be able to suggest a way around your real problem.

Agreed, OP has not stated why #1 phillips is a requirement. I would think a tooling change would be fairly cheap (buy a new set of bits for under $10), far cheaper than making a non-standard screw. The problem with making a #1 Phillips #8-32 screw is that the torque required to screw/unscrew it may exceed the cam-out torque of the #1 Phillips. There is a reason why #8-32 screws use a #2 Phillips.

Why not go to Canadas answer a #1 robertson (US square) a #6 thread and a #4 thread are a #1 size robertson 1/4 or 3/8 length no problem the bit is easier to use on a machine cost of screws @ $C2.39 for 100.

Did you try 'Small Parts, Inc"? They have a wide selection of fasteners.

http://www.smallparts.com/

I don't know where in the world you are but we buy 4-40 UNC x 3/16" 100° c'sk pozi drive screws in the UK from PTS-UK. I can't see from their data what size the drive is but it might be worth contacting them.

Why not consider a "Robertson" other wise known as a square drive.

I call it a Phillips that works!

There is also Torx and Allan heads

if not Mcmaster did you try Fastenal, www.fastenal.com

If its not a standard item, you will pay more

Did you try US Micro Screw? www.usmicroscrew.com