Screwdriver Handle Upgrade

I will explain how I make a replacement handle for a Harbor Freight screw driver.

You will need:

Lathe.

Lathe chisels.

Harbor Freight screwdriver Kit.

Ferrule, This one is from a piece of one inch copper tubing.

5/8 inch Fostner Bit.

7/16 inch twist drill bit.

Other shop tools as necessary.

These used to be free, we were able to pick up several for a class for around $2.00.

Place the handle in a vice with the fitting facing up. Use a sharp wood chisel and cut down the outer edge of the fitting to just past the bottom of the fitting.

Insert the screwdriver in the fitting and pull down hard to remove the fitting from the old handle.

This step is not necessary. I have included it to show how I came up with the measurements needed.

The outer length of the handle is around 4.2 inches.

The inner length of the hole is about 4 inches.

Again, this is just showing the measurements.

The length of fitting is just a bit more than 1 inch.

The outer diameter of the fitting is about 5/8 of an inch.

The inner diameter is about 7/16 inch.

The length of hexagon area is just a bit more than ½ inch.

For the wooden handle we will use a piece of wood about 1 1/2 to 2 inches square.

I mark off the length of the original handle and add a half inch or so and then add another inch or so to make a tenon on the wood to hold it in the chuck.

Mark the centers of the wood and use an awl to punch a guide hole in the wood.

Use a mallet to set the Star drive in the end of the wood.

Insert the drive into the lathe and bring the tail stock up and fasten it securely.

Use a roughing gouge or your favorite chisel to turn the blank round.

I use a template to measure the diameter of the tenon and then use a parting tool to turn a tenon on my block of wood.

Remove the drive center and use the tailstock to help center the wood in a four jaw chuck and turn the handle to approximately the size you want. Remember, you will have to drill a 7/16 inch hole nearly the full length of the handle so do not make it too small. 

If you do not have a ferrule, you can skip this step.

Measure the inside diamater of the ferrule and then mark the length of the ferrule on the end of the wood.

Turn the tennon on the end and using epoxy cement, attach the ferrule to the wood.

Replace the live center with a Jacobs chuck and insert a 5/8 inch Fostner drill bit. Using the mechanism measure the end of the Fostner bit and place a piece of tape on the bit to use as a depth gage.

With the lathe speed at around 500 RPM or so, advance the drill slowly to the mark on the bit. Be sure to hold onto the chuck as you advance and remove the drill from the work piece. There is a chance that you could pull the chuck out of the tailstock.

Be careful when removing the Fostner bit from the chuck. It will be hot.

Replace the Fostner bit with a 7/16 twist drill bit.

I place a mark at 4" on the handle to show me the depth of the hole.

Measure 4" up the drill bit and place a mark.

Slowly drill the center hole to the mark on the bit. Be sure to withdraw the bit occasionally to clear the flutes of the bit.

Replace the Jacobs chuck with a cone center and bring it up to help stabilize your work.

Finish turning your handle however you like. Just remember there is a hole down the center.

You can use a burning wire to burn some decorative lines in the handle.

Once you have the handle to the desired shape, sand through the grits to about 320 or so.

I use sanding paste as a finish for the wood.

Using a parting tool or a saw, cut the handle off of the lathe.

I place a 3 inch sanding disk in the chuck and sand the end of the handle and finish it with sanding paste.

Using 60 grit sandpaper I rough up the edges of the holding mechanism.

Coat the mechanism with epoxy cement and place it in the hole on the handle.

Let it cure over night. If any of the cement leaks into the inner hole of the handle, use the 7/16" drill bit and insert it in the hole to clean it out.

You can make the handle any size or shape you desire. I made one for a client with arthritis that was about two inches wide. She loved it.