Pete,
You did not have to repost Jim's explanation; it was clear. I've used #0 x 3/8" wood screws for KD's for decades, but only on cars made of wood.
But for all plastic and brass I drill, tap, and go the 2/56 route. There are some good reasons for that.
And, I disagree with about providing drill sizes, etc -- giving novices a complete "how to" is the easiest way to make it foolproof. It's when they try something and use the wrong sizes of drills, taps, screws, etc and have problems or fail that their frustration sets in and they walk away wondering why they ever bothered and/or start using your name in vain,
The more succinct and simple, a variation on the KISS principle, the better this will work for novices.
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