Screwdriver Handle

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Introduction: Screwdriver Handle

About: I get a real kick out of completing projects with as low a budget as possible. It's usually pretty easy to collect almost all the parts necessary to make some pretty cool stuff. I also enjoy playing music an...

I've seen people online take a cheap, store bought screwdriver and make a new handle for it, replacing the uncool plastic one that it came with. So, after I got a few of these screwdrivers from Harbor Freight, I thought it was finally time for me to see what I could do. I made this as a gift for my dad, and it seemed like he liked it quite a bit. So, I feel like this is a good gift idea, and I may make a couple more to have ready for the holidays.

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Step 1: Dismantle Screwdriver

This particular screwdriver that I got was super easy to dismantle. I ran the handle through my band saw, but you could obviously use any type of saw to cut the handle. There's a little metal piece that holds the insert in place. It just takes a couple of minutes to extract this metal piece and set it aside for later. At the end you can epoxy this metal piece into the handle that you make to finish the project.

Step 2: Start Preparing Your Blank

For my blank, I wanted to use several different contrasting woods. I was just using little pieces of scrap wood that I didn't want to waste, so I began by running them through the table saw, just to get some flat edges. I then cut the all to equal size and glued them up into little "sandwiches" and let them sit for a while. I then cut my "sandwiches" into little cubes. The cubes were then glued back together, but switching their orientation to make sure each cube was placed opposing the last.

Step 3: Finish Up Blank

After the cubes had time to sit, I would run the entire glue-up over the belt sander to make sure it was completely flat. Then, once again, I glued the stacks of cubes together. To try to be clear, I had four stacks of cubes that I glued up into two halves. The halves were then glued together to make one blank.

Once it was all one piece, I cut the two sides flush on the miter saw. Then I made sure to mark the center on each end, and I went ahead and cut off all four corners on the band saw to save some time at the lathe.

Over at the drill press, I drilled a hole the exact diameter of the insert that we removed earlier. I made sure and put tape on the drill bit at the depth I was shooting for, so I would know where to stop drilling. Then I switched to a smaller bit and drilled out the entire cavity in the handle for the insert to go down into. I used the screwdriver itself to check and make sure it was deep enough.

Step 4: Turn and Finish Handle

With the blank all ready, I put it on the lathe and turned it round. I wanted to keep this handle fairly simple, so I had to practice quite a bit of restraint, because it's in my nature to over complicate things. After it was to the shape I wanted, I noticed a small gap between a couple of pieces, so I filled it in with epoxy and let that cure.

Then I sanded through all the grits of sandpaper that I have. I can't stress enough the importance of sanding. When you think you've sanded enough, sand some more.

I put on some paste wax before removing it from the lathe, and gave it a little while before buffing it to a nice shine.

After your handle is complete, all you have to do is epoxy in the little piece of metal. I covered it in epoxy and then had to tap it into place with a mallet. It was a super tight fit and after fifteen minutes or so, it was ready to go.

Just insert the screwdriver and your finished!

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1 Person Made This Project!

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13 Discussions

0
rsauve999
rsauve999

2 years ago

I'm making an electric drill powered lathe. This technique has inspired me

- it will be my first project..

0
rsauve999
rsauve999

2 years ago

How do you know where to cut off the handle, without cutting into the metal?

0
Alex 2Q
Alex 2Q

2 years ago

I really like the finished pattern! This could also work great for knife handles. You got my votes!

0
_TheKnexGuy_
_TheKnexGuy_

2 years ago

Cool idea! I love the end result! I voted for it and I hope it wins.

0
epiphanyww
epiphanyww

Reply 2 years ago

Thank you for the kind words.

0
aCuriousCreator
aCuriousCreator

2 years ago

Wow that is really beautiful :D Nice work! And I love the video

0
deluges
deluges

2 years ago

Good job. No you can go stab someone with it. They'll call it "overkill"

0
Anna-Grace
Anna-Grace

2 years ago

It looks so nice! Great job!

0
ClenseYourPallet
ClenseYourPallet

2 years ago

Why? Why not! If you have the ability, why not make something more awesome? Beautiful job

0
DIY Hacks and How Tos

I really like wide handles like this. It makes it a lot easier to apply torque.

0
epiphanyww
epiphanyww

Reply 2 years ago

That is exactly what I was going for. Some tool handles are just to thin and you can't really grip them. That's the beauty of making your own, customization.

0
kode1303
kode1303

2 years ago

I love it! Sometimes people ask why. Why when you can just buy one? They don't know the minds of tinkerers.

0
epiphanyww
epiphanyww

Reply 2 years ago

You got that right! Story of my life. "Why did you do that?" "I have no idea."