Custom Hex Key T-Handles

Overview:

Yet another set of T-handles for allen wrenches.  I've tried several others but ultimately wanted to design one that could work for just about any wrench.  I liked the overall design by @Will which utilized a threaded core that secured the wrench in the handle, so that was my primary inspiration.

Customization:

I designed Fusion 360 files to be fully parametric and can be customized for wrench sizes 1.5-10mm or 1/16" - 3/8".  There are two parameters that are set as favorites, and are the only two parameters that need to be changed, unless you want to do further customization:

Wrench_L_len - The distance between the outside of the shaft to the tip of the wrench, measured on the short side of the allen wrench.  This primarily drives the length of the channel within the handle for the short side of the wrench to slide into.  NOTE: do NOT enter a value less than 16mm, or the handle threads will get trimmed.

Wrench_Size - The stated size of the wrench which is hexagon's side to side measurement.  This will drive the hole diameter of the threaded core as well as the diameter of the handle's channel.  The diameters will be calculated based on this size using hexagonal formulas.  This will also be the text displayed on the handle.  The “ParametricText” plug-in is required for this feature:

https://apps.autodesk.com/FUSION/en/Detail/Index?id=2114937992453312456&appLang=en&os=Win64&autostart=true

Another parameter worth mentioning is “Clearance”.  This will be used a number of ways and will be magnified in some cases.  I print these handles with a 0.6mm nozzle diameter and 0.32 layer height.  Depending on your printer, you many want to adjust this.

I created two Fusion 360 files: 1. For wrenches going from 1.5 - 5.5mm or 1/16" - 7/32", and 2. wrench sizes 6-10mm or 1/4" - 3/8".  Each file is essentially the same, but most of parameters for each are set to generate a specific size handle.  A smaller handle for the smaller sizes, and a large handle for the larger sizes.

Note: depending on the wrench size, some of the fillets will get messed up on the outside of the channel.  You can either ignore the errors, or recreate them for the new size.

Imperial Considerations:

Everything is done in metric.  To create the imperial set, I still measured the “Wrench_L_len” in metric, but entered the Wrench_Size as inches.  The text on the handle would then be in thousandths.  I like the look of fractions, so I manually updated the text parameter each time to display a fraction instead of decimal.

Knurling on the Core:

This is optional, and I have the steps for this grouped and suppressed in the timeline because it adds a lot of processing time.  If you are making your own custom handle and core, you would need to unsuppress that group if you wanted the knurling. 

Assembly:

I recommend fully threading the core into the handle before trying to insert the wrench.  This will clean up the threads.  Depending on your printer's accuracy, you may have issues fitting the smallest sizes into the channel.  I slide a flat head screw driver down the back of the wrench's shaft as I place it into the handle.  Then pry a bit to force the short size of the handle into the channel.  This has only happened occasionally on the 1.5mm and 1/16" wrenches.

Included Files:

I've included handle and core files for each standard metric size from 1.5-10mm and imperial sizes 1/16" - 3/8".  I've also included a 3mf file that has a metric set for the wrenches that come with most Creality printers: sizes 1.5-4mm.  You can view the storage tray I designed specifically for these handles to attach to a 20x20 rail here:

https://www.printables.com/model/714308-allen-wrench-storage-for-ender-printers

Print Details:

Printed on an Ender 3 Pro with 0.6mm nozzle and 0.32 layer height.  No supports required.

I designed my handles from scratch within Fusion 360, but they were heavily inspired by Will's design.  My handles encase more of the short side of the allen wrench, the threaded core is easier to thread on and off, I added knurling to provide a little more grip, and I moved the text to the side where they are more visible.