On the other hand the potential to be able to use many different bit types is appealing, plus I like the ability to replace worn out screwdriver bits, which is a big reason I retired my Vic Spirit (yeah I know Vic will replace it).
So my solution is to find impact grade drill bits and grind them down to fit the bit driver. This allows me to make them any length I want (or whatever length the tool will accommodate) and gives me a whole hardware aisle of options. And when I wear one out and it starts slipping in screws they're cheap and easy to replace. I mostly only use a Philips here but I like that it's easily replaceable.
So anyway I start out with these that have a longer full size end, because that's the part you need to grind down to fit. You can't use the ones that only have an inch or so of shank, at least not if you want the bit to stay in the tool full time.
Then cut down to the length you need, and remember you can grind down the butt end if it's too long but you can't add it back if you make it too short. The shorter bit here is one I made for my Supertool 300, the new one will be for my Arc. Turns out I can use an even longer bit in the Arc if I bend the "bit retention arm" out of the way. This thing is supposed to stop the factory bits from flying out of the bit driver if you use the hammer end of the tool but it didn't help anyway so I bent it straight so these longer screwdriver bits can get past it.
I do the majority of the metal removal on a mini bench grinder, and then clean it up with a Dremel and slowly file-fit it to the bit holder. On this Arc since there's potential to hammer with this tool, I want the bit to fit as tight as possible into the holder so it has less chance of flying out. You need to be mindful of the shape of the Leatherman bits so they fit the same way, and try to keep the sides as square as possible.
Lastly I didn't get a picture but I use a thin carbide disk to cut a small notch into the bit where this little retention spring seats. It really doesn't make much difference as far as retention, but I didn't want the spring sticking up either. I also cut that little notch on the bottom of the head because it was hitting the head of the pliers and not closing as far as it could, this won't effect use at all.
Now it does stick out a little bit, and the bit driver doesn't actually close ALL the way but the tip of the bit doesn't stick out any further than the knife does so it doesn't bother me. It's a fair compromise for a significantly better screwdriver.
