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Originally Posted by Andrew Blair
I've heard of using a sharpened Allen wrench, after hardening it. Unfortunately, I doubt it would perfom on a high carbon or stainless steel.
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Andrew;
here is an article supporting your idea.
It is from the Home Shop Machinist, 2002 Sept.-Oct. Issue page 36
titled:
"Make Your Own Socket Head Fasteners with the Brinkerhoff Rotary Broach".
It is an interesting approach and does use a hex key that is sharpened and hardened. Unfortunately the magazine does not provide online copies of the article. Enjoy Larry Upjohn.