Turnigy Hex Screwdriver Handles

I've owned this set of Turnigy hex screwdrivers for well over a decade. They work fine for smaller projects, but when I'm using them on a bigger project, like building a printer, the handles really bother me. They're too small, and my hands get fatigued after a dozen or so screws in a row. Recently picked up a nice set of nut drivers from Wera, and the handles inspired me to finally do something about my hex screwdrivers.

I indicated these are Turnigy screwdrivers, but I have seen these same handles on many sets on Amazon and other sites. These handles are most likely compatible, but measure the distance between the highest points on the handle, and the distance between the flats. The widest diameter should be around 19.2mm and the distance between flats should be about 16.6mm. The depth of the pocket for the handle is 80mm. If your drivers fit that shape, these handles should work.

Here are 2 variations of this handle design, which is meant to be pressed over the existing handle. I highly recommend you print them with TPU and a little fuzzy skin on the outer walls. The combination is really comfortable. They could be printed in a different material, PLA or PETG, but the TPU, even a high shore rated TPU, has that subtle give that just makes it more comfortable. TPU isn't going to crack or break if dropped, unlike most other filaments. If you can print in TPU, it really is the way to go here.

The first variant is the one in the picture. The second variant has deeper contouring, and more hex to the profile. I'm trying both, but they both feel nice to me. Both feature a hex section at the bottom for extra grip.

Printing:

• Use TPU, PETG is probably the second best alternative.
• 0.2 layer height is fine.
• 15% infill should be good.
• Fuzzy skin on outside perimeters only.
• 0.2mm on fuzzy skin thickness.
• 0.3mm on fuzzy skin point distance.

That's it, print away. You will need to press the handles on, or use a dead blow hammer to gently tap it on. I used some scrap wood with a hole for the shaft of the driver, and a dead blow hammer to gently tap the handles on.