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[mklotz]

You can find freely downloadable plans for all of Elmer's engines here...

http://www.john-tom.com/html/ElmersEngines.html...

[mklotz]

I've had good results with Sharpie paint markers...

https://www.amazon.com/Sharpie-37371...000GOYAPQ/ref=...

[mklotz]

I've made numerous tips and tip extensions for (non-Starrett) DIs and in all cases the thread was 4-48. I know that because I had to buy a 4-48 tap and...

[mklotz]

Or you can use an old drill press vise...







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[mklotz]

I get a value for the new diameter just slightly different from your value of 34.395 mm.

D = 35 mm
P = 1.5 mm

pi * D /...