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All three methods will work to varying degrees , however +/- .005 on a thread depth seems kind of tight to me. The only way I can think of holding +/- .005 would be to thread mill them. As to the varying chamfer depths , what up with that? Are these parts being made on a drill press ? You may...

One way to gage the depth of the thread would be to grind "whistle" notches for a "go" depth and a "nogo" depth on a thread plug gage. Another down and dirty way is to count gage rotation until the gage bottoms out. turns X pitch of threads = depth

I've had excellent results using Roller burnishing on lathes as well as machining centers. There are several manufacturers of this type of tooling. Cogsdill comes to mind. Google them , they have an informative site. You will have to finesse speeds and feeds.

A part I am running requires drilling (3) .078 dia holes 1.8 deep. Mat'l is cast 420f s.s. Live tool through coolant is not an option. I am currently using a G83 peck cycle with full retract to clear chips. per peck length = .078 RPM=3000 Feed= 4.3 IPM. Drill is cobalt TIALN coated parabolic...

Check this site out http://www.uscti.com/TapsFinal2.pdf

http://www.sugino.com/products/db/e_yotoprod_b.asp?seq_no=11517 We have had much success with this companies tools. also Cogsdill

select toolpaths select next menu select transform select geometry for creating sub check box for sub programs select whether its to be abs or inc post normally

Does anyone out there have any experience with 420F? What are its advantages over 300 series stainless? I understand that there aren't many mills state-side that will produce it

When our quality manager came out to the machines , he couldn't stand hearing......"They don't check too bad if you don't check em to good".

Emuge offers an excellent chart for NPT min hole depths