Drill bit size for KK 100 headers

[TheWinterSnow]

So I recently found out that while CAD programs libraries with the Molex KK 100 connectors use a 0.0312in drill hole, that the header will not fit into the board.  I found the size of the header is 0.025in but it is a square.  Using some quick math I found that to get the edges of the square I would need a hole of 0.0353in.  Since I need to order a new drill bit for this purpose, for those that have used the kk 100 connectors, do you use a 0.035 (#65) or 0.036 (#64), which one is better or are they both off and is something better?  I ask because I have to order them, no local stores, even specialty stores don't carry bits that small and they aren't cheap, so getting the wrong one wastes time and money, and could possibly ruin a board if the bit is too big.

[davent]

Have you tried a model/hobby shop for that size of drill bit. No doubt only HSS bits but at least would give you a chance to try the sizes out first hand before you order expensive carbide bits.

and I'd go bigger,  #63 or 62.

dave

edit, I drill all pcb holes first with a #71 carbide bit which covers the vast majority of my needs, then if needed will enlarge a hole with one of the bigger numbered HSS bits i have available, most often a #65.