I made a mistake on my drill hole sizing on a board, and the through plated holes for my header pins were only drilled to .028", instead of .040". Do any of you know of a header pin with round tails that will fit in a .028" hole?

 

Just mount the header pins in a Dremel tool or power drill/drill press and use a grinding stone on the spinning half to hand mill it to the required size. As long as it's only one board and not a huge number of pins it shouldn't be too difficult. The header pins can be marked with a permanent marker and removed with a pair of pliers easily. Depends on exactly how many header pins you're talking about.

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I could do that, but it is more like 50 boards. I found two companies that may make pins that will solve my problem, Mill-Max and Commcon.

 

You might find something like that at Samtec.
Jeff

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Nothing is impossible for the man who doesn't have to do it himself - Weiler's Law

 

I don't know if Mill-Max makes separate pins that small. But they do have headers with pins down to at least .018" diameter, available at mouser.com et al.

What kind of header do you need? i.e. What is the spacing and number of rows? And do you need male or female?

- Tom Gootee

http://www.fullnet.com/~tomg/index.html

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I want .100" spacing, 1 x 10. I want .025" square pins on one side, and round pins that will fit into a .028 hole on the other.