Re: Square Hole
That appears to be a wobble or rotary broach. You can buy a rotary broach tool holder and 8mm broaches (hex and square) from Littlemachineshop for a reasonable price (from memory $100 for the holder and $35 for the broaches). You can also spend $700-$900 for a holder from Sommatool, PolygonSolutions or Slater and broaches for $50-$70 or $300 for some external broaches. You can get virutally any shape you want.
I have the LMS one but have yet to try it. Given the quality of other LMS stuff I have bought I don't have high hopes for it.
They are all limited to a depth something like 1.25-1.5 times the width of the broach, i.e. a 1/4 broach can cut a shaped hole up to 3/8 deep.
You can also buy square push/pull broaches where you drill a hole and then force them through with an arbor. I haven't tried one of those but have been tempted to buy one to see if it works.
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