True enough. But to be honest, I suspect that I wouldn't need to make more than 20 bits (in a reasonable length of time, anyway). So the majority of those Allen keys will sit on a shelf unused.
I will. I actually feel a bit bad not making the screwdrivers, but there's always a point at which you have to decide what you're going to make and what you're going to buy. Right now I have too many projects on the go, and making screwdrivers seems less appealing than the other projects I'm working on. But when I find a worn screwdriver that I no longer want, I'll have a go at grinding it and see how neat it turns out.
Doesn't the sleeve prevent you from seeing if the bit is located in the slot?
Personally I think that sometimes a slotted screw head is needed for appearance. On some devices, a Phillips or Allen head looks wrong.
I've never seen square drive wood screws. Must be an American thing.
Sometime I might get a manual torque limiting screwdriver, but for the time being I'm managing without.
Mostly on electrical equipment made between the 1930s and 1950s, together with a few on clocks. You could certainly buy those big "cheese head" screws in England up until recently. I bought some 0 BA screws in that style a few years back, but when I went back for more, they were no longer available.
The ones I've had break were made from a clear yellow plastic. When the plastic broke, it looked almost like glass. I didn't hammer them. It was torque in normal use which caused them to break.
Best wishes,
Chris