Have you ever looked at a screwdriver set and thought “There are more sizes than I’ll ever need” only to read reviews and find out they’re incomplete?
Getting a set that has the sizes you need most can often be more important than buying a “full set” that lacks one or two vital sizes. But how do you know when you have all the necessary sizes? Read on to find out more about the various screwdriver sizes available for the five most common screw head shapes.
Flat Head Screwdriver Sizes
Commonly referred to as a slotted screwdriver, these have the wedge-shaped blade that any child immediately recognizes. You can often use a slotted screwdriver to work heads with a slightly bigger slot or even Phillips (or other cruciform style) heads in a pinch.
Unfortunately, the way flat head screwdrivers are measured can be frustrating, as the thickness of the tip is rarely given. The good news is that the width of the tip and the length of the shank are presented in the measurements provided. These measurements are presented as width by length (for example, 1/8″ x 4″).
The shank length will affect whether the screwdriver can fit into a deeper recess (perfect for automotive work) or if it functions best where there’s very little room for your hand. Note that the length of the handle is proportionate to the length of the shank, so short-shanked drives also have short handles.
See also: Parts of a Screwdriver
Slotted Precision Sizes Chart
| Tip Width (SAE) | Tip Width (Metric) |
|---|---|
| 0.8 mm | |
| 1 mm | |
| 1.2 mm | |
| 1.5 mm | |
| 1.8 mm | |
| 2 mm | |
| 3/32" | 2.5 mm |
| 1/8" | 3 mm |
| 3.5 mm | |
| 5/32" | 4 mm |
Slotted Standard Sizes Chart
| Tip Width (SAE) | Tip Width (Metric) |
|---|---|
| 3/16" | |
| 4.5 mm | |
| 5 mm | |
| 7/32" | 5.5 mm |
| 6 mm | |
| 1/4" | 6.5 mm |
| 5/16" | |
| 3/8" |
Phillips Screwdriver Sizes
This popular cruciform drive has become a standard in many countries. Less prone to slipping than slotted screwdrivers, the design still has some issues at high torque that have since been resolved in newer cruciform designs. As with slotted screwdrivers, Phillips drives are popular in precision work, being a staple in laptops and other electronics.
To an extent, Phillips screwdrivers may be used on any cruciform screw, although there is an increased risk of cam out and damage to the head. Part of this is the fact that a Phillips driver is sized through a number code instead of an Imperial/SAE measurement and can fit two to five sizes of head above its own.
Phillips Precision Sizes Chart
| Phillips # | Tip Width (Metric) | Fits Screw Sizes |
|---|---|---|
| #0000 | 1 mm | |
| #000 | 1.5 mm | |
| #00 | 2 mm | |
| #0 | 2.5 mm | 0-1 |
| #1 | 3 mm | 2-4 |
Phillips Standard Sizes Chart
| Phillips # | Tip Width (Metric) | Fits Screw Sizes |
|---|---|---|
| #2 | 3.5 mm | 5-9 |
| #3 | 5 mm | 10-14, 16 |
| #4 | 6 mm | 18, 20, 24 |
| #5 | 8 mm | 5/8" and 3/4" (machine screws) |
Pozidriv Screwdriver Sizes
This screw drive is often referred to as an improved version of the Phillips drive. Instead of the Phillips’ pointed tip, tapered flanks, and rounded corners, a Pozidriv has a blunt tip, parallel flanks, and an additional small rib between each slot. This allows for increased grip between the bit and fastener.
While you can fit a Phillips bit in a Pozidriv fastener, it will likely cam-out before you can fully tighten it. A Pozidriv bit will not fit inside a Phillips fastener. Pozidriv bits have a “PZ” marked on them along with five common sizes.
Pozidriv Sizes Chart
| Size # | Wood Screws | Machine/Tapping Screws | Metric Screws |
|---|---|---|---|
| #0 | #0, #1 | #0, #1 | M1.6, M2 |
| #1 | #2, #3, #4 | #2, #3, #4 | M2.5, M3 |
| #2 | #5 to #9 | #5 to #10 | M3.5, M4, M5 |
| #3 | #10 to #16 | #12 (or 1/4", 5/16") | M6 |
| #4 | #18 to #24 | 5/16" to 1/2" | M8, M10 |
Hex Key Screwdriver Sizes
Hex keys are named because they have a smooth hexagonal shank and no head. More commonly referred to as Allen wrenches, these screwdrivers sometimes come in an L-shaped shank with no handle, as multiple retractable sizes with a centrah handle (ala Swiss army knives), or even with a ball-shaped tip.
Measurements for hex keys is done via AF (short for across flats). To measure an unmarked key, for example, you would measure the distance between two opposing ends. This makes it easy to determine the key needed for a specific hex screw when you’re not sure of the size.
Hex Key Sizes Chart
| Tip Width (SAE) | Tip Width (Metric) |
|---|---|
| .7 mm | |
| .9 mm | |
| 3/64" | 1.2 mm |
| 1.3 mm | |
| 1.5 mm | |
| 1/16" | 1.6 mm |
| 5/64" | 2 mm |
| 3/32" | 2.4 mm |
| 2.5 mm | |
| 7/64" | 2.8 mm |
| 3 mm | |
| 1/8" | 3.2 mm |
| 9/64" | 3.5 mm |
| 5/32" | 4 mm |
| 11/64" | 4.4 mm |
| 4.5 mm | |
| 3/16" | 4.8 mm |
| 5 mm | |
| 13/64" | 5.2 mm |
| 7/32" | 5.5 mm |
| 15/64" | 6 mm |
| 1/4" | 6.4 mm |
| 7 mm | |
| 5/16" | 8 mm |
| 9 mm | |
| 3/8" | 9.5 mm |
| 10 mm | |
| 1/2" | 12.7 mm |
Robertson Screwdriver Sizes
Popular in both construction and electrical fields, the Robertson drive (commonly referred to as the square drive) is more common in Canada than the US due to licensing problems earlier in its history. Now that the original patents and licensing restrictions have begun to expire, Robertson screws are gaining in popularity worldwide.
Much like Phillips screwdrivers, Robertson drives use a numbering system. What sets these apart, however, is that all sizes are also color-coded for easy reference.
Robertson Sizes Chart
| Color Code | Size # | Fits Screw Sizes |
|---|---|---|
| Orange | #00 | 1-2 |
| Yellow | #0 | 3-4 |
| Green | #1 | 5-7 |
| Red | #2 | 8-10 |
| Black | #3 | 12, 1/4" |
| Brown | #4 | 5/16", 3/8" |
Torx Screwdriver Sizes
Sometimes referred to as the star drive due to its rounded 6-point star shape, the Torx drive is designed to function at higher torques and have a longer lifespan than other popular screwdriver types. This has made them quite popular in both electronics and automotive industries. They can also be used as an emergency substitute for hex drives, although there’s a higher risk of stripping the head.
Torx drives use a numbering system based upon the distance between two opposing points. Unlike other driver measuring systems, the same numbers on a Torx screwdriver apply to both SAE and metric scales. You can identify the size required for a random screw by measuring the width of the slot and comparing it to a Torx sizing chart.
Torx Sizes Chart
| Torx Size | Width (SAE) | Width (Metric) |
|---|---|---|
| T1 | .031" | .81 mm |
| T2 | .036" | .93 mm |
| T3 | .046" | 1.10 mm |
| T4 | .050" | 1.28 mm |
| T5 | .055" | 1.42 mm |
| T6 | .066" | 1.70 mm |
| T7 | .078" | 1.99 mm |
| T8 | .090" | 2.31 mm |
| T9 | .098" | 2.50 mm |
| T10 | .107" | 2.74 mm |
| T15 | .128" | 3.27 mm |
| T20 | .151" | 3.86 mm |
| T25 | .173" | 4.43 mm |
| T27 | .195" | 4.99 mm |
| T30 | .216" | 5.52 mm |
| T40 | .260" | 6.65 mm |
| T45 | .306" | 7.82 mm |
| T50 | .346" | 8.83 mm |
| T55 | .440" | 11.22 mm |
| T60 | .519" | 13.25 mm |
| T70 | .610" | 15.51 mm |
| T80 | .690" | 17.54 mm |
| T90 | .784" | 19.92 mm |
| T100 | .871" | 22.13 mm |
Related Posts:
- 14 Different Types of Screwdrivers and Their Uses
- Parts of a Screwdriver (with Diagram)
- 6 Best Screwdriver Sets for the Money
What is the M2.0 screw refered to in this Lenovo S340 service guide? https://i.imgur.com/3QByFQu.jpg
That would be a machine screw. The 2.0 is the diameter and 8 is the length (both in mm).
Being Canadian having worked with every type of screw out there Robertson are are far and away the best ans seem to be the fastest way to go. Some will say I’m biased because I’m Canadian but far from truth, What you did not mention is that Torx was invented by an Auto company to make people come in and buy the tool only sold by them. There is a new screwdriver out now and I’ve found it mostly in electronics. It looks like Torx but has a knob in the centre of the screw. So far only seen small ones . Thanks for the charts and mentioning colour coating. Actually a great idea. It just seems easier to look for a green or a red rather than searching for size.
Thanks for the comment JK.
You are correct about Torx being invented by an auto manufacturer; General Motors, in fact. They used this “new” screwhead in headlight trim to make it impossible to replace a headlight (back when that was a regular wear item) unless you purchased a tool from the GM stealer, er, um, dealer. The tool was expensive at, IIRC, around $12 which is equivalent to about $40 today. They were a cheaply made screwdriver-style with two sizes available.
Robertson even refused to license, that is really….
Bosch made one type P2R2 bits, its not double ended bit, but one bit fit both PH2
and your beloved RED 2.
How about an actual size photo of every size? A picture is worth a thousand words.
“To measure an unmarked key, for example, you would measure the distance between two opposing ends. ”
Would that be between opposing flat faces, or between points?
The flat sides.
what’s the size of Pozidriv screwdriver
Updated the article to include Pozidriv sizes.
Please do one for Y-Screws (or Tri-Wing Screws), I’ve literally been searching on & off for YEARS now…-Thanks a lot Nintendo(!)
I concur!!! I don’t understand why it is sooooo difficult to find a size guide for the Tri-wing/tri-point heads! I have been looking everywhere with no success either! Any help would be greatly appreciated!
I get soo confused about the whole ‘difference between a screw’s drive size & screw size’ part 🙁
I appreciate your site as I am trying to make up a set of as many complete sets of drivers complete with individual handles permanently attached as a gift for my son.
I have been in the electrical and basic electronic trade since 1952 as an apprentice tradie anl later in my own small business in which I apprenticed my own two sons, working in industry then after CABGs surgery and a stroke as a teacher. I can’t stop trying to fix things
Thank you.
Thanks for the comment Bill. What a fantastic gift idea for your son. Yes, I’m sure many of our readers can relate as far as having a hard time trying to fix things. I wish you the best.
I have more of a question. My retractable screen door needs the screws replaced, mainly because one is not biting into the wood. I have to repair the wood first, but my question is the company that installed it told me that the screw is a Robertson. I would need Robertson#1 screwdriver to screw it in with once I have repaired the wood. I have stripped the head on the screws because I tried to take them out with an Allen wrench. What other wood screw sizes will fit the opening of a Robertson Screw that would need a #1 screwdriver?
Thanks
Gonzo
Maybe I’m not understanding the question but a Robertson #1 will work with screw sizes #5, #6, and #7.
GM did not invent the Torx. Bernard F. Reiland did.
https://www.legacy.com/obituaries/rrstar/obituary.aspx?n=bernard-reiland&pid=107223629
The development of the Torx screw began in 1967, was patented in 1971 and was invented by Bernard F. Reiland for the then Camcar Textron company.
https://www.hausoftools.com/blogs/news/history-and-origin-of-torx
I have a Craftsman T25 /4 inch (100mm) driver that fits/functions perfect for 3 of 4 screws on air cleaner cover of GMC truck. The 4th screw needs to have a 6 inch shaft to be comfortable for a larger hand to manipulate. Is there a T25 / 6 in.(125mm)? A substitute for Craftsman would be ok just so it has the 6 point star configuration head to fit screw.
A reply would be appreciated. Rob