Well, I got my "extra" hex block back in July, and finally got around to putting it in the mill:
Now we'll see if I can keep track of what I'm doing when using it, or if I end up with a 10-sided hex!
The big advantage of spotting drills (in the “normal” sizes) is that they are available with 120 degree points - very close to 118 degrees - whereas center drills are 60 degrees.
Joe Pie made a small square “collet” for one of his miniature machine builds. IIRC, he milled a rod to half-round, milled a 90 degree groove in the flat face, parted off two lengths then sandwiched the square stock between them in a 5C collet. I’ll try to find the video in the morning.
I haven’t had issues with my Bondhus allen wrenches (ball end keys & screwdriver style, all “Protanium”), not even the 0.050” one. The good news is they have a lifetime warranty, and I don’t think you need to return the bad one(s).
Using distilled water in cooling systems always starts a debate. One side says it prevents hard water calcification. The other is that distilled water is “hungry” and can promote corrosion in systems with dissimilar metals [hungry water was discussed at length by The Tappet Brothers, Click &...
380/3/50 is common outside the US (460 x 50 / 60 = 383.3333etc). 460/3/60 motors will run, but 17% slower (which can be an issue with fan cooled motors).
The advantage of case hardening is that you get a long-wearing part with a tough interior. Hardened & tempered steel would be tough, but may wear faster.
That said, in a model engine hardened & tempered would probably outlast the intended use.
Unfortunately out of stock, and $300+, but Clough42 was impressed by the quality of the matched pair of Shars 6” vises he bought and I would expect that the 4” would be similar:
Little Machine Shop has some very good vises as well: