There was a thread awhile ago about the specification for the Phillips screwdriver, and I proposed that it could be done with a grinding wheel with a 90 degree Vee shape. https://bbs.homeshopmachinist.net/forum/general/80264-ot-maybe-phillips-driver-tip-geometry
I have been thinking about it for a while and I might try and make a tool that will work for this. Here is the concept, using a 4-1/2" angle grinder disc:

The model actually shows a 1/4" wide wheel, but the ones I have are actually 0.15 to 0.19 inches. I will need to make a mandrel for the 0.875" diameter hole, and a way to power it. I will first need to use a diamond dressing tool to get the right shape, which probably should be done at a moderate speed. I have some 1/8 HP 12V DC motors that will probably work OK for this, and I have some XL timing belts and sprockets with which I can get the speed that will work. I had considered doing it on the lathe, where I can make use of the compound to get the 45 degree angles, but I've heard bad things about grinding dust getting into the works and causing problems.
Another way to do this might be a single point tool, but it would need to be held at a radius of 1" to 2.5" or so. Maybe a flycutter could be set up for the purpose? But I think grinding will be better for existing screwdriver points, as they are hardened.
I have been thinking about it for a while and I might try and make a tool that will work for this. Here is the concept, using a 4-1/2" angle grinder disc:
The model actually shows a 1/4" wide wheel, but the ones I have are actually 0.15 to 0.19 inches. I will need to make a mandrel for the 0.875" diameter hole, and a way to power it. I will first need to use a diamond dressing tool to get the right shape, which probably should be done at a moderate speed. I have some 1/8 HP 12V DC motors that will probably work OK for this, and I have some XL timing belts and sprockets with which I can get the speed that will work. I had considered doing it on the lathe, where I can make use of the compound to get the 45 degree angles, but I've heard bad things about grinding dust getting into the works and causing problems.
Another way to do this might be a single point tool, but it would need to be held at a radius of 1" to 2.5" or so. Maybe a flycutter could be set up for the purpose? But I think grinding will be better for existing screwdriver points, as they are hardened.
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