Original screwdriver runs with 4*1.5v non rechargeable cells. I modified the battery system with 5 rechargeable cells, So that we can get 6v to run the screwdriver perfectly. I also found difficulty in handling the screwdriver without handle. I thought to add handle at low cost and for easy handling. It costs half of the original rechargeable screwdriver (with handle).
Step 1: Prototype
This is my prototype made with plastic toy gun. This also worked well but not as strong as I desired.
Step 2: Parts and Tools Needed
- Electric screwdriver
- Push to ON switch
- Slide switch (forward / reverse)
- 2 * Nut and bolt
- PCB clad
- Battery holder (Cut the spring)
- 6 mm MDF
- 4 mm MDF
- Wood glue
- Drill machine
- Soldering iron
Step 3: Design and Cutting
- Cut 3 pieces of template 1 from 6mm MDF.
- Cut 2 pieces of template 2 from 4mm MDF.
- Glue 6mm MDF's.
Step 4: Cutting Grooves
Cut grooves as shown in picture so that the battery, switches to be fitted.
Step 5: Drilling Holes for Wiring
Drill holes as shown in pictures
Step 6: Disassembling Screwdriver
Disassemble the screwdriver as shown in pictures.
Step 7: Drilling Hole for Screws
Drill the holes as shown in the pictures.
Step 8: Wiring
Step 9: Finishing Handle Part
Step 10: Setup for 5th Battery
Step 11: Making the Stand
Cut 2 wood pieces for making stand as shown.
Step 12: Final Step
I filled the gaps by mixing wood dust and glue. Finally paint it.