How to make Torx screwdrivers or Allen keys

 by aerodude

Step 7: Results

I think the outcome is quite acceptable. I actually completed the Torx before starting the Allen key, so I did some things different then shown here. That caused it take a bit longer, maybe 45-50 minutes including taking pictures and other stuff. After that I started the Allen key, and when it was done, it wouldn't grip the screws at all. I almost gave up on it, but ended up successful after filing a bit off the end. It's probably a good idea to make the hexagonal section tapered, so that you can vary the thickness a bit.
All in all, the Torx is probably more suited to this method. Even though it appears more difficult, it is actually more forgiving in performance, once it fits. For the Allen key, the margin between fitting in, and slipping is very small. The soft metal used here also makes it easy to over-tighten the screws, damaging the screw driver. If that happens you have to file the damaged area away... An upside to this is that it is nearly impossible to damage the screws themselves. A big plus when trying to remove recessed screws.

Below you can see that the screwdrivers fit well enough for the screws to stick, just from the friction.

This completes my first instructable, I hope it will be of some use.

 
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haunted2097 says: Apr 29, 2011. 3:26 AM
Well done! I used this patent to make ultra small flat screwdrivers! You did very impressive work!
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