This code has a couple of problems. One is that the handling of filenames, particularly the method of extracting a number from them, is highly suspect. Once you think you've extracted $number, try printing both the full filename and $number.

It looks like you're trying to accumulate a list of thread nubmers that contain matches. Since you say that $thread_data[0] is the same as $number, this might be easier like so:

my @dat_files = <$bboard/*.dat>;
my %found = ();
foreach my $file ( @dat_files ) {
    open(DAT, $file) or die "$file: $!";
    while ( <DAT> ) {
        my @thread_data = split "|";
        if ( $thread_data[4] =~ m/\Q$in{$for}\E/i ) {
            $found{$thread_data[0]}++;
        }
    }
    close(DAT);
}
[download]

The keys of %found are now the thread numbers taht contain a match, and the corresponding values are the number of matches.