p.s. If you like this instructable, vote for it in the Celestron Space Challenge!
Step 1: The Stuff
A magic marker, probably crayola, since the body is wider than others.
A cheap pen. try and get one that narrows towards the end, but it's okay.
1 push button switch. Maybe a slide switch if you want.
1 small buzzer. the round case type is important; make sure it will fit inside.
1 audio jack, female. this will be used to recharge whatever small battery you can cram inside.
1 power source. get a small rechargeable battery, or a supercapacitor. It took me some time to find one.
And, most importantly, a Tirefly. It's a little bike light that clips to the wheels somehow; it has the perfect shape for the screwdriver head. Substitute something else if you have to. You can buy a set here.
Get some scissors, a craft knife, and some pliers. Also superglue. And a drill. Plus the regular soldering stuff.
Step 2: Prepare the Body
Step 3: Making the Head
Step 4: Finish the Body
Step 5: The Insides
Step 6: Put It Together
Step 7: Almost Done
Notes about charging: just grab a cable and plug it in. You can strip the other end to expose the wires, or, like mine, if it's a double male you can plug in another jack and use alligator clips. Remember to use some common sense and don't blow up anything; both batteries and supercaps should not be overcharged.
Add your own modifications, too. One idea is an IR LED paired with an IR phototransistor and some other device so you can actually "sonic" it. Another idea is to add a red setting. Have fun with it!
So, grab your trusty sonic, and go open some doors!
Step 8: Going Further...
I drew up a little schematic below, and with some jiggery-pokery and a thin speaker in place of a buzzer it just might fit inside.