just bought keyed alike boot and door handles. There is no thread in the end of door handle shaft.
does anyone know if this should have a screw to expand the slotted end or should i tap it if so what size.
My old ones had a metal screw but a smaller size.
drilled hole in new handle is is 4.7mm .185"
thanks

On the last set I fitted, I ran a tapped a thread using a 10-32 UNF tap in the existing hole. This gives enough thread to secure the handle to the lock using a pan head 10-32 machine screw and washer. if the handle boss is also screwed to the door using 10-32 screws and appropriate spacers (see Ebay link below)then there won't be any issues with the handle coming loose (not all handle bosses have the threads tapped though).
http://www.ebay.co.uk/itm/Mini-Mk-1-2-D ... 20fdc1bfbe

Thanks wild_willy
i thought it would be UNF.
I drilled out 10mm stainless steel nuts for spacers inside door perfect height.
What a bastard of a Job. you need pixie hands to do up the bolts.
handle shaft sticks through about 3mm making the handle float.
will machine up a spacer washer to fit over square shaft and not foul on the door lock body. i don't really want to cut short the shaft

So by 10/32 you mean 5/16. ?

#10 UNF is same as 3/16 X 32 TPI. anything under 1/4 UNF has a number.