A message close to the head problem email is:

> On 10 May 2018 at 12:22, Gene Heskett <[email protected]> wrote:
>
> > This would, if a 3/4" R8 collet could be found with a D shaped bore, be
> > yet another way to remove one potential slip point in trying to hold a
> > tap for rigid tapping.
>
> Buy a small-bore R8 collet and have it wire spark-eroded to a D-shape, 
> perhaps?
>
> (You could consider plunge-eroding it yourself, I suppose)
>
> --
> atp


I suggest using a Broach.


A specially crafted hand tool, " . . . forced through an opening, or along the 
outside of a piece of work, to enlarge or change the shape of the hole or to 
form the outside to a desired shape."

The descriptive text is taken from "Technology of Machine Tools, seventh 
edition.

The book has no guidance on how to specify broach sizing.


Putting in Broach to Google led me to "d shaped broach",

and the sixth link was a 
www.practcalmachininst.com<http://www.practcalmachininst.com> reference to a 
2005 question.


James Isaac.

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