Dear all,
I thought I’d update on my progress. I bought some wedges, but using these just seemed to pull the spindle further downwards in the quill. I eventually realised that you are supposed to use the wedges against the slightly wider diameter ring just above the Jacobs taper on the end of the spindle, not against the body of the drill as I was. (see pictures below). In the end, I removed the body of the drill off the pillar, turned it upside down and drilled and tapped an M8 thread in the back of the chuck body, which allowed me to easily remove the chuck. Now I can take the chuck off easily whenever I like. Unfortunately, after a clean and rebuild the chuck is still not holding drills true (one of the jaws looks to be worn on the side it grips the drill. i wonder if filing the other two down to suit would improve this?
EDIT: I noticed that when the spindle had been pulled down further by the action of the wedges, this introduced some play into the spindle (disaster!). However, the spindle was easily moved back up by exerting some downwards pressure on the re-installed chuck against the table.
An better way of drilling the hole would have been to mount the drill bit in a machine vice rather than taking the body off and using a hand drill. The machine vice is in the post!




