I’m 99% certain you won’t get an M5 die to go over a 6mm starting diameter, even if you have one that opens up really wide. A2 stainless will make your life extra difficult (though it won’t be any easier with normal shoulder bolts because they’re case hardened).
Your best bet in the absence of a lathe is probably your ghetto method. File it down roughly by hand first and then finish it in the drill. If you need a full 10mm of actual thread, you’ll need to go 1-2mm further because the die won’t thread all the way to the end. Lots of grease in the die.
I think I'm better off just using an M5 and then putting some shrink wrap over the first 5mm of threads. I just got all excited about being able to have an M6 bolt to fill up the 6mm hole
Maybe sleeve a long M5 with 6mm x 5mm brass tube? Bond the sleeve in place with Araldite or Chemical Metal if it needs to stay in place. I take it this is still for your bar-ends / mirror fittings.
I’m 99% certain you won’t get an M5 die to go over a 6mm starting diameter, even if you have one that opens up really wide. A2 stainless will make your life extra difficult (though it won’t be any easier with normal shoulder bolts because they’re case hardened).
Your best bet in the absence of a lathe is probably your ghetto method. File it down roughly by hand first and then finish it in the drill. If you need a full 10mm of actual thread, you’ll need to go 1-2mm further because the die won’t thread all the way to the end. Lots of grease in the die.