
What
are you willing to pay for a good screwdriver?
The
answer to that question, of course, depends entirely on your
expectations. For some, a $6 #2 Phillips from Home Depot will satisfy
both the need and the budget. Screwdrivers, to a large extent, have
become disposable commodities within our present-day, mass marketed
tool culture. Many of us buy them inexpensively to use for our
routine tasks and assume that we'll eventually need to buy another
one someday. Screwdrivers get abused, borrowed, lost. They are
utilitarian items.
On
the other hand, if you're a collector, a period furniture specialist
or a hand tool woodworker who places priority on the look, feel and
performance of every tool you purchase, your expectation of a "good"
screwdriver might prompt a different answer to the question. A
screwdriver may carry the same value as a premium plane, chisel or
fret saw in your tool chest. It is an end in itself.
If
you're in the latter group, you're exactly the customer for whom
Elkhead Tools is building premium screwdrivers, one small batch at a
time. In fact, the wait for receiving an Elkhead Tool order can be
three to eight weeks. But that doesn't deter customers from waiting a
spell for the drivers to arrive. In a market where nothing else
compares to a handmade driver, the wait is worth it.
Elkhead
Tools, which was only launched a little more than a year ago, is the
result of the efforts of two Denver-area orthodontists, Gary Benson
and Dave Lindeman, and Chuck Pyne, a self-employed machinist. All
three consider themselves to be hobbyist woodworkers who were
interested in filling a void in the premium hand tool marketplace for
screwdrivers.
"We
were in Dave's shop one night and started kicking around the idea of
developing some woodworking tools that could be improved upon,"
Gary recalls. "The three of us had noticed that the topic of who
makes good quality screwdrivers kept coming up in some of the online
hand tool and woodworking forums we follow... Quite honestly, the
answer to that question at the time, was no one. We not only wanted
to satisfy the niche for other hand tool woodworkers; we also wanted
to own better screwdrivers ourselves...we wanted to make screwdrivers
that performed as well as they looked, on the level of, say, a Blue
Spruce chisel or a Lie-Nielsen plane."
So,
in their spare time, the three started to develop screwdrivers with
Old World character, made of the highest quality and embodying a
great aesthetic: in other words, heirloom tools. Their aspirations
led them to a final design of hand-turned cocobolo handles, solid-brass ferrules and hardened tool-steel shanks. One look at these
screwdrivers is all it takes to realize how far they separate
themselves from the rest of the pack. These are definitely not your
plastic-handled, "big-box" specials.
Gary
explained that there have been a number of challenges associated with
developing what he considers to be the "rebirth" of
heirloom drivers. The first was to overcome certain limitations of
traditional wooden-handle screwdrivers -- they needed to improve what
actually led to the development of plastic-handled screwdrivers in
the first place.
"After
trying numerous iterations, it didn't take us long to figure out that
there's really no good way to affix a round, hardened-steel shaft
into a wooden handle. Old screwdriver designs relied on stamped wings
on the shaft, but those needed to be driven into the handle.
Eventually, they would come loose. That's why plastic handles
became the standard. We wanted to use cocobolo for our handles which,
although very hard, is also brittle. It wouldn't accept driving the
shank into the handle by force. We tried epoxies, set screws and
various pinning methods only to finally conclude that the real
solution was to develop a better ferrule to accomplish the
handle/shaft connection."
That
challenge led to Elkhead's solid-brass ferrule, which is joined to
the steel shank with industrial retaining compound. Gary says the
adhesive, used in industry to set keyways on motor shafts, makes it
all but impossible to separate the ferrule from the shank without
destroying the brass. They consider it a permanent bond.
The
ferrule, which Chuck mills on his CNC equipment, is machined
with a square cross-section that fits into the wooden handle.
The square interface resists the rotational forces of twisting the
screwdriver during use, and it creates a "slip fit" for the
cocobolo. Epoxy or CA glue is all that's required to bond the handle
to the ferrule. Gary adds that Elkhead's hefty ferrule design also
contributes to the driver's overall feel and balance. Much of the
interior of the handle is brass, and that added weight, according to
Benson, helps to set an Elkhead screwdriver apart from a
mass-produced driver. It's got the right ergonomics.
While
the company will make driver handles from nearly any species of wood
a customer requests, Gary says cocobolo is the favored choice of the
three owners. "Its range of hues and colors make it the
best-looking wood around. It's also hard, durable and maintains the
classic look and feel of a lot of the old coveted rosewood handles on
other hand tools." Gary turns each handle on a conventional
lathe, after cutting the square hollow for the ferrule with a
mortising machine. Dave carries out the final sanding, finishing and
assembly of each screwdriver.
Even
though the initial product design took some trial and error, those
challenges were fairly easy to resolve for the three inventors. The
single biggest frustration these days, Benson says, is finding
reliable sources for materials, given the modest volumes and level of
quality Elkhead requires. "If you want to order 100,000 pieces
of a particular part, it's easier to get that sourced than if you
only need 10. For the tool steel, brass and handle stock we need,
it's very time-consuming work to find the right suppliers," Gary
comments. "It's amazing how many people I've talked with and how
much time I've spent on the phone finding the right sources."
For
example, the screwdriver shanks are currently supplied by a German
company. Benson believes the quality of the steel and the precision
milling of the tips make these shafts the best-fitting, most reliable
and accurate screwdriver shanks on the market. But finding them
required a global search that led him to China, Germany and
elsewhere.
A
second challenge circles back to the original question I posed: the
cost/value proposition. Benson believes there will probably always be
"the uphill battle" of bucking the $20-per-set screwdriver
mindset that's prevalent for this type of tool. In contrast, Elkhead
screwdrivers, which are made in three sizes of Phillips, flat blade and
Robertson tip styles, sell for around $75 apiece. Sets range in price
from $225 for three drivers to $675 for nine. But the challenge of
selling premium hand tools for higher prices in a mass-produced tool
market goes with the territory. Those who already embrace the
philosophy of handmade hand tools, on the other hand, usually don't
need to be convinced of the value equation. In fact, Gary says the
easiest "sells" are to other toolmakers, which come as
welcomed affirmations to the new company. "Dave Jeske (owner of
Blue Spruce Toolworks) once told me, 'I'd much rather buy a set of
screwdrivers from you than figure out how to make them myself.' And
here's a guy who earns his living making tools!"
Other
accolades come from collectors and professional woodworkers such as
Canadian woodworking instructor Duncan Robertson. Gary says
Robertson, "who owns one of every Lie-Nielsen tool ever made,"
once ordered a set of four Elkhead screwdrivers with square-drive
tips. "When I delivered his order to him, Duncan, who
French-fits every tool into his tool cabinet, already had a drawer
custom-fitted and waiting for those drivers to arrive."
Benson
says master woodworker Frank Klausz is partial to Elkhead flatblades.
He owns a set of three.
So
far, Gary, Dave and Chuck are pleased with the success of their
drivers and the growing visibility of Elkhead in the hand tool
marketplace. Gary and Dave travel to several shows per year, but most
marketing happens by word-of-mouth or through the company's website.
Numbers of sales are "still in the hundreds," Benson says,
"and we'll be adding a zero soon." That seems to suit the
owners just fine. The three are committed to "slow growth"
so they can continue to be responsive to the needs of their customers
and develop future products that really fit a discriminating hand
tool clientele. The product line already extends beyond screwdrivers.
Elkhead also offers precision brass dowel center drills for making
handmade wooden dowel hinges. The drills ensure perfectly centered
holes for the hinge pin. Soon, the company will offer a table saw jig
that will allow woodworkers to mill dowels from any wood species,
again to facilitate wooden dowel-hinge making, which is one of
Benson's passions. Plans are also in the works to begin fabricating
custom cocobolo handles for fret saws, and Elkhead is considering
making brass and cocobolo levels, too.
"We're
not a mass production company, and we never will be... Ours is a very
personal, hands-on approach to toolmaking. As hand tool woodworkers,
we appreciate the connections we have to other toolmakers whose tools
we also use in our own work. I think there's a real yearning among
hand tool woodworkers for that personal connection to the toolmaker.
That's what we want to embrace."