DIY Turned Wooden Screwdrivers

Wooden handled flat-head screwdriver

Owning or having access to a wood turning lathe gives you almost limitless opportunities to turn useful everyday household items. One of the more essential tools in your home is the flat-head or Phillips-head screwdriver. Making your own turned wooden screwdriver not only gives you a source of pride, but a beautiful tool that you can use often on common chores around the home and shop. They also make memorable gifts for your family or friends.

Things You'll Need

• 6-inch long square wood turning blank at least 2-inches in diameter.
• Screwdriver Kit (flat-head or phillips-head)
• Wood turning lathe
• Drill chuck with assorted drill bits
• Roughing gouge
• Sandpaper
• Mineral oil or some other suitable finishing oil.
• 5-Minute epoxy
• Vise or bench clamp.

Instructions

1. Mark an "X" across each end of your wood blank by drawing a straight line from one corner to the next. Turning the piece 90-degrees and repeat the process. Where the two lines meet is the center of each end.

2. Mount the wood blank between centers on your lathe using the "X" on each end as your guide. Turn the lathe on a medium speed and, using your roughing gouge, cut the corners off of the blank until you have a round, smooth cylinder from one end of the blank to the other. Continue to round and smooth the blank with the roughing gouge until it is approximately 1.25-inches in diameter.

3. Remove the blank from the live centers and replace the drive spur in the headstock of the lathe with a four-jaw chuck. Clamp the rounded blank in the four-jaw chuck and, using the roughing gouge, lightly cut the piece until it runs true and smooth.

4. Replace the drive center in the tail-stock with a drill chuck and insert a drill bit slightly larger than the diameter of your screwdriver kit's hardware. Turn on your lathe and drill a hole in the end of your blank to the depth of 1.5-inches. Test the hole for fit using the screwdriver hardware. If too tight, move to a slightly larger drill size and repeat this step. When satisfied, remove the tail-stock and drill chuck from the lathe and set aside.

5. Cut and shape your screwdriver's handle on the lathe to a contour that is pleasing to your hand. If your screwdriver kit comes with a ferrule, then shape the end of your blank to fit the inside diameter and length of your ferrule. Stop and test fit and refine shape until satisfied.

6. Sand the handle to the smoothness desired while it is still on your lathe and finish your project with a light coat of mineral oil. Part or cut the screwdriver handle from the rest of the blank and sand the end smooth and touch up with mineral oil.

7. Place the finished screwdriver handle in a vise with the drilled hole pointed straight up. Mix together 5-minute epoxy and coat the bottom 1-inch of your screwdriver rod in the epoxy and insert into the hole of the handle until it touches bottom. If needed, tap lightly with a hammer. Wipe off any epoxy that may be pushed to the surface. Ensure that the screwdriver rod is perpendicular to the handle. If your screwdriver kit includes a ferrule, repeat this step for the ferrule. Allow the epoxy to cure for 24 hours before using your new wood screwdriver.

Tips & Warnings

• You can purchase screwdriver parts through a specialty hardware store.

• Small square wooden turning blanks can be found at specialty hardware stores.

• Most screwdriver kits have a flat-head or Phillips head bit that is 1/4-inch in diameter.

• Screwdriver handles are typically 4-5-inches in length, 1.5-inches in diameter at their widest and 3/4 of an inch in diameter at their smallest point.

• Use an existing screwdriver handle that you like as a guide for cutting and shaping your wooden screwdriver handle.

• Once you are proficient at making screwdrivers, experiment with more exotic woods for handles to make a memorable keepsake or special gift.

• Follow all manufacturer safety instructions before working with tools and products.

• If you are unsure about an operation, obtain competent professional instruction before proceeding.

• Wear all necessary safety devices during wood turning, and observe safe wood turning practices to prevent accidents and injuries.

References

• Wood Magazine; 4-in-1 Turned Handle Screwdriver Woodworking Plan, November 2007
• Turn a Wood-Handled 4-in-1 Screwdriver; Highland Hardware, 2006
• Shop-Made Tools; American Woodworker, February 1994

Resources

• Make your own custom heirloom screwdrivers #1: Start to Finish