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Zippo Shell Precision Screwdriver Set
A precision screwdriver set with 12 bits (or 11 plus an extender) that fits inside a Zippo lighter shellMaker/DIY
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Inspired by Laura Kampf's Zippo Bit Safe: https://www.youtube.com/watch?v=zIqTdPbxGBY
I loved the idea behind Laura Kampf's Zippo bit safe, but only including four bits seemed like a huge waste. I also use precision screwdrivers much more often than these full-sized tool bits, so I decided to design a version around them.
This set includes a precision screwdriver handle, which doubles as an adapter to a full-size (1/4" hex) bit. The insert to hold the bits is 3D printed, as well as a driver end with a rotating head (using a 623 bearing) that allows it to be used like the precision screwdrivers that typically come with these sets. The insert holds the main driver/adapter piece, plus 12 of these smaller precision driver bits. In place of one of these 12 bits, you can include an extender as shown, but you will have to cut it down a little to fit inside the Zippo shell.
Earlier versions used a friction closure like Laura Kampf's version, but I couldn't find a way to make that work in this version without wasting the very limited space or making the bits hard to remove. Instead, I cut a length of a 1/4" wide pocket tape measure to use as a spring to hold the lid shut.
Materials and methods
In addition to the printed parts, you will need:
- Parts from a precision screwdriver set. This one has everything you need, including the unique 1/4" hex adapter that has a knurled grip and functions as the driver body (it is also used as a handle to pull the insert out to access the bits): https://www.amazon.com/gp/product/B071R6SVDX/
- 1 623 bearing (pressed into the rotating driver head).
- 1 M3 button head screw, 8mm long (threads directly into the plastic of the driver body).
- 2 M3 washers (to keep the screwdriver head from rubbing against the body).
- The shell from a Zippo lighter (any full-sized Zippo should work).
- The spring is made of two layers of tape measure material, cut from this pocket tape measure: https://www.amazon.com/gp/product/B00009OYGH/
- 2 10mm diameter, 1mm thick neodymium magnets glued to the bottom of the insert help keep the bits in place. They can also be used to keep screws from getting lost when you remove them.
The extender that comes with the set is a bit too long to fit in the Zippo shell. If you want to use it, you'll have to cut down the end to make it fit. Just use a dremel tool and make the hexagonal part the same length as the tool bits.
For the closure spring, I cut two pieces of the measuring tape (you could also try using the spring from the center of the measuring tape, but I found that it was too brittle in my case). I bent the ends over a couple of times with needle-nose pliers (a 90-degree bend seems to hold, trying to sharply bend it 180 degrees will break it), then I inserted them under the tab in the lid used for the original closure mechanisms and bent the tab down over them to hold them in place (this also gives you a little more head room for the driver head/extender to fit).
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