Thanks Geof,
I dont have a preferred way. I only have a sample from our customer. I would prefer to tap but nobody will make it. I agree the shank diameter is way to small. If only one pc was needed I could probably cut the thread in several different passes, but the qty's for this job are around 25,000, so I need a solid process. Someone is making it now somehow, but they will surely not tell me
Thanks for the help.
By the way, somehow I posted this in the wrong forum. Sorry about that.