When thread timing is critical, as others have said, its time to look at thread 
milling.

I have a repeat job for a company doing warranty retrofits, having to replace 
an out of production assy with a replacement made by a different vendor.

The replacements are mounted on the rear side of the front control panel .47" 
thick Al. I have to provide #6-32 threads with a usable depth of .400" without 
any visible change on the front.

Once you get your head straight on standard thread milling you can go for the 
bonus Migraine round and try NPT thread milling! (which I also do a fair amount 
of)

Greg

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