Goldilocks approach to self-tapping holes

Maybe this is the approach we need to take with the self-tapping holes?

Some previous discussions we had on this:

as well as the repo with our attempt to engineer a solution:

Interesting to read about some of the reasons for the holes not coming out the designed size.
(My RC friends would be horrified by the idea of the specific example, a control horn without the correct number of splines)