Front rotor bolts

[DucatiBastard]

I have had rounded Allen heads that I was able to remove with that tool, one thing that helps is to use a top quality Allen socket and grind a small hollow in the end. This makes cutting edges that can use the part of the screw head that has not been compromised, down at the bottom where the other bit has cammed out. You can't see it, butt at the bottom of the recess in the screw head there is still flat spots!

Spike, can you clarify this? Are you putting a circular hollow in the end of the bit, similar to a tamper-resistant Torx? Or more of a slot?

This seems like an interesting mod

[krista]

@DucatiBastard, probably more like a "dome"... I did something similar recently to cut holes. If the allen is 5mm or 6mm, if you go at the end straight on with a 1/4" ball endmill or even a 1/4" drill, it will make a concave end that will have a sharp edge.

... curious if this is what SpikeC did...

[SpikeC]

 That is affirmative, I use a small grinding point to make a cup in the end of the bit, so it has edges. Stock Allen bits always have rounded corners on the end, which encourages camming out.