I don't have any real projects going at this time so I have been thinking about making a couple chuck keys for the chucks I use the most. I don't really have any good chuck keys. I like good tools so something to my standards would be nice. I can't visualize how I might make the square engagement part though...using just a lathe.
I'm thinking I could use my power hacksaw to cut the square part and clean it up with a file but before I do I want to see if anyone else has tried this and has anything to share.
I'm about as lazy as can be, so I USED TO .. just BUY the square part ... and fab a Tee handle.
'
'Got more money, started using socket-wrench tee handles.
Got older and wiser, just buy several chuck wrenches, all sizes, throw the f*****g "ejector" spring nonsense in the trash bin, keep a stash handy.
Some start at all of nine US dollars. Some cost more.
They might strip or bend? Pilgrim? They HAVE to.
The CHUCK is the hard and costly part to repair. The wrench is MEANT to limit the amount of damage "Bubba" can crank into it with a cheater bar.
Price the actuator pinion on a scroll chuck. Or the screws of a four-jaw.
Which one woud you want to fail first, at how much spend, and how long a downtime?
Annnnnd...
Lots of "stuff" around a shop needs my
time that I CANNOT so easily "just buy".
So.. at least you might be well-off to "just buy" the squarey-ish part?
All it needs is the corners chamfered. BFD. Bench grinders exist.