Grind to fit is the only way to go. Whether it’s a cheap screwdriver or an expensive screwdriver, it’s still cheaper than the gun you’re working on. If you have a grinder, good stock to work with can be found all over the place. I routinely pick up spare magnetic tips at hardware stores for less than .50 and then keep them on hand for when I need to grind to fit. I don’t worry too much about it being too hard or two soft because I’m very careful when I have screwdriver in my hand (except when it’s a home improvement project; in that case, I’m just plain dangerous).
Like the carpenter’s old saying, “Measure twice and cut once.” I always prep anything that’s about to receive a screwdriver. I clear the bench to make ample room, check for anything underneath that will scratch. I always position myself where I have a good view at what I’m doing and I try to be directly over the driver whenever possible. Lastly, I take it easy and if it’s not working, I look for alternative ways before throwing more muscle at the problem.
