Here's a wacky idea: let's try to use a Dremel grinding disc to cut a notch in a screw, and make a DIY self-tapping screw!
Step 1: Looking at Screws
The difference between a regular screw and a self tapping screw is in the tip. The self-tapping kind has a notch that cuts out some material and allows it to engage in material with less effort.
Step 2: Grinding
With a Dremel grinding disc, it's easy to create the notch on a regular screw. Thus making the DIY self-tapping screw.
Proof of concept: check! Although, a freehand grinding approach is not ideal.
Step 3: The Jig
A block like this would be great to hold the tool, and guide the screw into the grinding disc.
Step 4: Drilling
Hole for the Dremel tool.
Step 5: Marking
Locating the hole for guiding the screw. Use the Dremel to mark expected depth of the grinding disc.
Step 6: More Marking
Then use a square to mark the expected edge of the grinding disc.
Step 7: More Drilling
This hole will guide the screw.
Step 8: Expected Result
With the Dremel set up inside the jig, this is what should be seen looking through the screw guide hole. The grinding disc is visible in one quadrant.
Step 9: Using the Jig
Making self-tapping screws with a Dremel is much more precise now.
Step 10: Performance Test
As expected, the self-tapping screw requires noticeably less pressure to engage.
Step 11: Don't Breathe This
Screw smoke... don't breathe this!
HIGH FIVE for reading :)