canadianhorsepower
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Thanks, all, for the comments and suggestions. Rod, my dividing head doesn't have enough power to turn make threads.
I'm going to try using my tool and cutter grinder to grind the hex heads. I think that will give me a better finish. Also, I probably won't fill the sockets since I would like to continue to use allen wrenches with them.
I would buy the hex bolts, but they don't have the sizes I need. For the head bolts, I need 4-40, 1.25" long. I would also need a hex head of 5/32 across the flats. The smallest that I've found available are 3/16".
If I made them out of hex stock, again, can't find any 5/32" hex available. I can get 1/8" or 3/16" in 12L14 and nothing smaller than 3/16" in 303 stainless.
I was really just looking for a quick and easy way to make the SHCS's less obvious.
Chuck
did you check this supplier
http://www.jimorrisco.com/index/product/id/66