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Ah - thanks for the tip! I thought the size of the key that you use to undo the bolt corresponds to the bolt size but clearly that was too simplistic an understanding.. The Allday fork eyelets do seem to be M4 though.
Another question - what is the best way to secure the contents of a front basket to stop them from rattling around? Currently have bungee cords but they do a fairly poor job. I've seen people jerry rig inner tubes with carabiners which I quite fancy trying..
youClown
chiroshi
hugo7
Eeyorecore
Bottle bosses are M5. Any fork bosses that are M4 will be designed for mudguards rather than racks, but I highly doubt that is the case on the Allday fork. There is no chance they are M3.
It may be that the holes weren't masked properly and some paint has gummed up the threads. If you have or can get hold of an M5 tap and run that through it'll clean them out very easily.