Steve, what ever you make the key from, just make it long enough that the T bar misses the chuck jaws when they are fully out.
A handy thing I use on a bigger [8"] chuck when changing the jaws, it's the speed wrench/crank, from my 3/8" socket set, did try a square driver in a battery drill but the crank is faster. Ian S C
Edited By Ian S C on 02/03/2014 10:09:52