I’ve recently been working on a project that required me to use my micro screwdriver set. A common problem with this set was the inability to generate enough torque to remove the screws by hand. As a result I would often use a pair of pliers to generate more torque, occasionally damaging the screw head or over tightening them.

From a past instructable that I’ve read involving Oogoo, I’ve combined it with a new idea to resolve my issue. The solution is to make a new rubber handle over the existing one, moulded from a previously made product.

Step 1: Equipment Selection

1.Select the screwdriver you want to upgrade.

2.Find a decent feeling screwdriver or handle from any tool to mould.

Step 2: Bottom Mould

1.Create a container for the mould housing.

2.Use clay to fill the bottom half of the mould housing.

3.Press the handle into the clay and tape the mould housing together, making sure to prevent any leaks.

4.Mould the handle using plaster of Paris (a ratio of 2:1, plaster to water).

5.Pour the plaster in the mould housing and wait until it sets.

Step 3: Top Mould

1.Remove the handle and cured plaster from the mould housing and the clay.

2.Invert the mould and place it back into the mould housing with the handle.

3.Lubricate the bottom plaster mould with oil (I used car oil).

4.Pour in the top half of the mould with plaster and let cure.

5.Once set, separate the plasters from the handle.

Step 4: Casting

1.The casting material will be Oogoo which is GE Silicone 1 and corn starch. The ratio I used was approximately 1.5:1, cornstarch to silicone. Combine the two so that you get a consistent clay like substance. If it’s flaky and falls apart, add more silicone. If it’s still sticky, add a little corn starch. A little sticky substance is better than a flaky, crumbly mixture.

2.Don’t play around with the Oogoo too much, or else it will set.

3.When it is still soft, then place the mini screwdriver into the mould.

4.Add the Oogoo on both halves of the moulds and firmly press fit the two halves together.

5.Tape the moulds together and let cure.

6.After two hours, remove the screwdriver from the mould and trim off any excess Oogoo.

Step 5: Final Product

After discovering Oogoo, it became my new best friend. It’s a very soft feeling material, similar to that of an eraser. It’s cheap and easy to obtain. Best part is that it’s fun and easy to cast. The downside is the mess involve in creating it. Enjoy!