YOu will have to have a good, new, reamer to make the sides smooth enough to create the needed compression. A drill bit will not be enough. The stem, or piston, is about 2 1/2 long on mine. The casing is longer- 3 inches, not including the handle or knob on the top. One end of the stem is seated in a handle, and the shaft is about 5/64th inch. The whole drilled in the bottom end of the shaft to hold tinder is 3/16"and is drilled about 1/4 " deep. I have seen more primitive ones made of wood, and horn, that are longer, and larger in diameter. Mine is only 5/8" in diameter, making it hard to grasp in my large hand. The wooden ones have more clearance between the sides of the shaft and the hole, but they wrap string or cord around the front end, using a groove in the shaft about an inche back from the end, and grease the cord to create the compression. Since I do not have one of those I cannot tell you how well they work. I would think based on this one, that it would be easier to raise the air temperature to the flashpoint of the tinder if the shaft and tool were longer, giving a longer column of air to compress. I think 5-6 inches for the outer casing would give most hands the clearance so you don't get pinched slamming this down, and if you made yours 3/4 to 1 inch in diameter, you will get a better purchase. I would stay with the same small diameter of the shaft, because the wider that hole is, the more air it has to heat up. You are starting a glowing ember, not the Chicago Fire!