DIY Brace Bit

Brace bits are very fun to use. I have a 10" brace bit that works great, but I need something smaller for smaller jobs like screwing and countersinking. 6" brace bits were expensive, and after a long time of looking, I finally decided to make some myself. The hardest part of this project, in my opinion, is bending the steel. A metal vise is strongly suggested. It will make the job much easier. Keep them as straight as you can. Try to drill and adjust the bending when needed. Also, some of the materials I listed were bought from Canada’s Dollarama. You may have to find alternatives in your location.

Before you decide to try this project, keep in mind that the instructions do not show you how to create precision drilling tools. They are for simple screwdriving, countersinking, and some simple drilling jobs where precision is not important.

Materials you need:

1. 5mm steel rod with 9.25" length or longer. (Dollarama tent pegs) $2 CAD for 6
2. Electric Drill Chuck with 5mm hole. ($5 -$7 CAD) https://www.aliexpress.com/item/1005003439982106.html
3. (optional) 4mm-6.35mm Adapter ($6.5 CAD) https://www.aliexpress.com/item/1005004296236940.html
4. DIY handle
5. DIY head

Tools you will need:

1. Metal vise or Clamp. (for bending)
2. Saw
3. ruler, marker pen
4. (Optional) Drill and tap for adding locking ability to a 4mm-6.35mm adapter
5. (Optional) Heat shrink tube to fit the handle

I was lucky to find cheap tent pegs from Dollarama. They were just perfect for the project. $2 CAD for 6 steel rods is very good. Just to note that Dollarama only carries them during spring/summer if I remember correctly.

For the drill chuck, I strongly suggest using the keyed chuck. Although they are more expensive, they will lock drill bits much better than the keyless chuck.

The chuck can hold up to 4mm. So if you want to add the ability to use normal hex shank bits like countersinks, you should get the 4mm-6.35mm adapter. It is not a common item but is very useful for this project.

I used some rubber caps from bicycle handlebar cover ends, which I bought from Dollarama, and cardboard tubes left over from contact papers as handles. I really think you should come up with a better idea to make your own handle and head. ;)

First, mark the steel rod with a marker pen. The Dollarama rod has a length of 23.5 cm. My marks were around 2.5 cm, 4.5 cm, 9.5 cm, 4.5 cm, and 2.5 cm. You can try different ratios to fit your design.

Second, bend the first two parts. Since the tent peg from Dollarama was already bent once, I only had to bend the second part.

In my opinion, bending is the hardest part. Just make sure you bend it as straight as possible. A metal vise is highly suggested. I do not have a metal vise so I bent the the rods between the gaps of balcony walls, I also use a bar clamp for bending some area.

In this step, you will have to create your own handle. Because I do not have the skills and tools to make a nice wooden handle, I made one with a contact paper roll and a bamboo straw. The straw has a 5mm inner diameter and acts like the core, while the roll allows me to grab it. I used hot glue to fix the two ends of the straw to the center of the roll. I did not fill the inside with hot glue.

When it cooled down, I added a layer of duct tape to the handle to make it more durable. I then added some double-sided tape, followed by a heat shrink tube for better grip.

Lastly, I inserted the handle onto the steel rod. Just make sure the length of the handle is correct, or you might have problems bending it later.

Now finishing the bending. Note that if you did not bend it correctly, you will have to adjust it later.

You can install the chuck and head now. If you do not have a head yet, you should create one. I do not have the knowledge to make brace bit head, so I simply used a rubber cap I found on a bicycle handlebar cover I bought from Dollarama. I drilled a 5mm hole in the center and stuck the end in. It's not perfect, but it works okay. ;P

This is the last step. You will need to test drilling and see if it works okay. If not, you will have to check the bending. Make sure both ends are straight. Keep adjusting by micro-bending using your common sense until it works okay for you.

The drill chucks in this project can only hold up to 4mm. If you wish to be able to use normal hex shank bits, you can buy the 4mm to 6.35mm adapter. This is an uncommon item, and I found maybe two sellers who offer this product. I posted a link for the seller I bought from at the top.

Like all magnetic adapters, the drill bit will come out quite often when you pull. To fix this, I drilled and tapped an M2 hole and then used an M2 screw to lock the bit. The metal is not very hard, so it is simple to drill and tap. Using a drill guide is suggested to keep the drill straight.

I made three brace bits, each with a slightly different handle and head design. I actually use them more often than my 10" brace bit. They are very good at drilling and screwdriving, especially the one with the modded adapter. I am glad I did not buy a 6". These 4" DIY brace bits are much cheaper and work better for my tasks. :)