Clarrie,
They changed the procedure some time back that if an item was flagged by the x-ray operator for hand search, the bag had to have items removed by the screening officer. Don't know the background as to why it was changed.
WRT the allen key, you could have drawn their attention to
Regulation 4.65
(4) A person is authorised to have a prohibited item in his or her
possession in a prescribed aircraft if:
(a) the prohibited item is a tool of trade; and
(b) the person keeps control of the prohibited item at all times.
Tell em you need the allen key to tighten up your head set or something.
The tools that are listed in the regs as being "Prohibited Items" include:
Scalpels
Ski poles
Darts
Drills
Box cutters
Utility knives
Saws
Screwdrivers, crowbars, hammers, pliers and wrenches
I fail to see how an allen key could be construed by any screener to fall within this category of items able to be used as a weapon.