A little time on the grinder will flatten them out. I’ve had to grind them thinner too to fit a tight space.
I tend to round the heads over on smaller diameter bolts much more frequently than larger bolts for some reason. The 8-14 mm sockets/wrenches are the ones that cause me the most grief. Bigger diameter bolts, I rarely have a problem rounding any of those. Course that may be b/c most of the bolts I’m wrenching are 8-14 mm. But if the larger bolts are somehow less easy to round over, maybe that has something to do w/the motivation of providing the 1/2 drive sockets as 12 pointers.
Looks like we’re overthinking this issue. Stanley put in the sockets because it had them. Too many 12 point 1/2" drive sockets? Pack them in sets and get rid of them. Easy peasy.
There are times you need a 12 point socket, I have come across some high torque bolts that have a 12 point head and there is no other way to get them off. These have usually been in sizes and torque specs where you would use a 1/2 in drive. I have seen ARP head bolts with 12 point heads.
The larger sockets have a larger ratchet or you can use a longer breaker bar. You will be able to get the socket on the bolt or nut and get a longer turn with twelve point. Six point sockets might not allow you to even get the socket on so you can even use it. You might get it on the bolt but have no room to turn it. I’ve never broken a socket larger than five eighths. Twelve point sockets are generally good in larger sizes.
Check your small sockets for beveling on the inside of the socket. Some have too much beveling on small sockets and they can round off small bolts. I’ve found that grinding the end to remove the bevel and create a flat end makes a big difference.
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