I may as well add my 0.02p to this thread since it has long since answered the original question. I think the choice of screws used in quick change toolholders is partly to do with personal preferences and partly to do with what is available.
In my case I prefer the square headed bolts (5/16" UNC) but I accept that these are probably not available in 2BA or M5. I do have some toolholders with grub screws and I use those for tools that never need to be changed (indexable tips/parting blade etc). Because I dont have many holders the square headed bolts are a boon because they never get filled with swarf.
As regards putting plasticene in hex sockets! words nearly fail me, it falls into the 'shake and vac' category (throw stuff on the carpet and then remove it!). May as well screw a plate over the front door letterbox to stop draughts, you can always remove it when the postman comes. With Dickson type toolholders just unclamp and tip out the swarf.
Maybe someone should write an article showing how to make a set of polished brass dome topped, O ring sealed covers for protecting cap head bolts. (put in ME though as I take MEW)
I think 'sticking up bits' are what make Dickson toolpost so useful, and far less hazardous than the three (usually two) sharp tools poking out of 4 way toolposts.
Ian P
Edited By Ian Phillips on 23/04/2013 22:06:42