drill chuck key chuck

thingiverse

I had to obtain a new key for an old drill chuck that was rusted out, but the one I purchased from the store didn't fit because the peg diameter was slightly too large. I figured that I could simply grind the peg down to size with a rasp/file by inserting the key into another drill, but I couldn't get the key into the drill chuck due to the handles being crimped in place. I decided to create a fitting to mount the key in a drill instead. Slide one half of the fitting onto each handle of the key and use a zip tie to secure it in place, then insert the key into the drill chuck. I have no idea if anyone else might find this useful, but I just wanted to illustrate an idea that I was able to quickly implement and solve a problem that I had. I guess this could be a starting point for building a drill lathe or wire twister? Also as a bonus, this "chuck" can also be used to drive the key in another drill chuck when you're too lazy to turn it yourself? I designed this model using Wings3d and printed the file in PLA using low-quality settings with support. The finish is rough but the part was effective. Just a few quick thoughts on safety: obviously, drill chucks and keys were never meant to be used like this - if you ever have any reason to spin up a drill with parts like this on the end, be extremely careful! Wear eye protection and watch out for the spinning key handles. I didn't have any issues with my part, but if the part is broken or poorly mounted in the drill, of course, there is a hazard of parts being thrown from the end of the drill!