Repairing and re-using Allen keys.

Although I’m not keen on how easy it is to strip and round-off a small Allen key, I reluctantly accept they are very popular. What I have found is it’s not too difficult to repair a worn key by simply cutting off about 2mm from the worn end.
A worn allen key:

Worn allen key

Worn allen key

After cutting 2mm off the end (Dremel or similar tool):

Repaired allen key

Repaired allen key

Tips: Wear face and hand protection, as the whole allen key will heat up when you cut it with a power tool. After cutting the end will be razor sharp so use glass paper to take the ‘edge’ off.

Easy, takes about 10 minutes including the time to set-up and tidy-up afterwards.


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