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Request to do a small machining job

The rod is 3/16 at 4.7mm diameter
Can you elaborate on what rod you sourced? For example if its drill rod, they are typically ground with stated tolerance +/- 0.0005" My experience is they can vary that much across the axis (elliptical) as opposed to diametric but now we are getting into the weeds. Its pretty good stuff. But if you bought nominal stock of pretty much anything else, all bets off.

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Just eyeballing the size/fit I'd aim for something like 0.0005" diameter over shaft size but for this purpose could even be a bit more, say 0.001".
 
Having picked up most of my engineering skills in a metric environment I sympathise with the metric / imperial conversion pitfalls.

I find it fascinating that our Canadian weather forecasts can resolve predicted wind gusts down to 10m per hour accuracy. How about 96.56 km/h as seen on the Weather Network? Makes much more sense as the original 60 mph swag.

Totally agree with philipFROM-PNW. In fact I'd go further and propose the FFF system of units going forward. That way we can at least all be equally confused: https://en.wikipedia.org/wiki/FFF_system
 
All of my schooling as well as my first engineering job were based on the mixed Imperial / US standards of measurement. At the time, I thought gallons, Quarts, and ounces were too complicated and confusing. Little did I know that the metric system would soon run me over.

I remember a young engineer ordering a tiny little hook for a trunk tie-down that arrived on a flatbed and need a forklift to unload it. We laughed for months about that one. The construction industry in Canada is still not really metric. I still buy 2x4s, 4x4s and 4x8 sheets of drywall and plywood. One of the first metric sky scrapers in Canada needed costly custom windows because metric windows were simply not available. I seem to recall that the supplier went bankrupt over that one and nearly took the GC with them.

My wife gets her weather in Imperial and I get mine in metric. I had to laugh at @Manfred's wind speeds.
 
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