How about finding a chuck key with the required gear size and then turn the spigot down to the required size to fit the chuck. It doesn't have to be particularly accurate so could be done quickly on a lathe or even with a bit of careful filing in a vice.
If the key is does not engage the teeth on the chuck sleeve, you can press the sleeve forward slightly to close up the gear mesh. Conversely, if you have a key where the mesh is too tight, you press the sleeve backwards a little.
I have done just what Martin W suggests to modify a chuck key. Rightly or wrongly, I made the spigot a snug fit in the hole in the chuck body (tighter than the "genuine article" sometimes appears to be! )