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  • Don't take this the wrong way, but if you're a bit prone to rounding Allen head bolts, then you'll definitely round out Torx ones. Figure out what you're doing wrong that is rounding out the hex. If it's as simple as you're not using the right size key, then get a new or better set of Allen keys. Just because it loosely fits in the hole, Imperial doesn't fit metric or vice versa. If it's a ball-ended key you're using and that's causing it to round out, then use a straight sided one. If you're leaning on the key and mangling the sides, then don't do that. Etc.

  • Thanks Jonny, it might have been the allen keys that didn't fit right and that I was over tightening them because I didn't want them to come loose.

  • A Torx head can actually accept more torque for a given size bolt than a hex head .. as long as the proper Trox bit is used! The torx pattern has more bearing surface area to spread the tightening torque force over.

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