What size wire to use for 4-40 threading die
I normally use 4-40 threaded ends. Sullivan products sell them in packs of about 20, they are about 1" long (same as what comes in one of their pushrod packages). Then I take a piece of brass tubing, use as a coupler, that will fit over the threads and the appropriate size music wire and solder together. Sorry I can not remember the sizes. Make the brass coupler 1" long so that it fits about 1/2" onto both the threaded end and the music wire. Hobby shop "silver" solder, Stay Brite, Hobbico, although not real silver solder, will provide a strong enough joint. K&S brass tubing will work fine, just make sure you do not use their 1/8" soft brass tubing (used for fuel line setup). And make sure the solder is "sweat" up and into the coupler.
2 Piece