Makeing a chuck key

[Technical Ted]

I made one out of an old allen wrench and it is holding up very well. I also like using grade 8 bolts for things such as these when strength is required.

Ted

 

[benmychree]

Before tempering (drawing) verify that there is NO OIL RESIDUE on the part. The oil will turn color long before the steel does. [The voice of Experience]

After quench, the squared end should be brightened up with abrasive cloth so that the temper colors can be seen.

 

[ddickey]

I made one from rigid conduit and welded it to the shank. A quick job as I wanted one with a large diameter handle to fit my hands well. Consider using a large diameter tubing of some sort, you won't be disappointed.

 

[pontiac428]

I made this one out of 308 SS. The whole time I was turning it, I kept asking my self why the heck I used such a hard material. It doesn't need to be very tough, and if it's harder than your chuck it will leave dings on contact. At least it doesn't rust.

 

[rwm]

Stainless lathe chuck key?! Darn, now I need to replace all mine...
Robert

 

[dbb-the-bruce]

So the next part that I'm not sure about is how the tee-handle is secured to the main shaft. I (stupidly) just realized that on all of my other chuck keys it is rigidly fixed. I'd been imagining a loose fit and a clip or something.

I'm assuming that it's just an interference fit?

I can look up the tolerances and use a hammer, my arbor press or other force multiplier to make it work.

Is there a simple trick I'm missing?

BTW - that SS key is awesome!

 

[pontiac428]

I just drilled and tapped the top of that one for a 1/4-20 set screw (and broke a tap, of course), but you could certainly do a press fit. It is common to see a knurled press fit on commercial keys. The hammer approach would work well for that. Or you can get creative. At the end of the day, it's just a handle to turn a pinion gear. Like corkscrews and bottle openers.

 

[dbb-the-bruce]

The hammer approach would work well for that. Or you can get creative. At the end of the day, it's just a handle to turn a pinion gear. Like corkscrews and bottle openers.

Ha! what I love is that craftsmanship comes from thinking as much as doing. I could just drill a hole and use an old screwdriver.....
As far as the creative part, I usually err in the "too" side.