Originally Posted by peteco
Yes, Torx is best but occasionally I come across an odd size where the bit fits looser than I like. Maybe it is an in-between size that I don't have a bit for but I thought I had a full set. I had to grind down a larger size one time to get a tight fit.
Even a loose Torx seems to survive pretty well, even with power drivers, but I have seen the same as you have. I think some of it is poor quality of heading the screws by the low end vendors, as I have had too tight and too loose in the same sizes. Of course I have also seen that with the Robertson screws, too. The Robertson ones also have a tendency to not be headed deep enough a lot of times.