drill chuck chewing up my BC shaft

I have a 3/8 inch keyless chuck Dewalt drill that I hook up to my Barley crusher. The shaft on the BC had a very small slot cut into it to grab onto. Well my chuck is just chewing up that shaft, and I keep trying to get it to grab on properly but every time it loses grip it just sheers it more and makes it worse for the next time.

Tips?

I was thinking of having a deeper slot cut into the BC shaft but that would take some dismantling so I'd thought I'd ask before getting into it.

Thanks

Sounds like the shaft material is not super hardened. You could file flats on the shaft for the chuck jaws to fit onto.

The chuck shouldn't lose its grip like that if properly tightened. Get a new one.

that is the problem with a keyless chuck on round shafts. it's nearly impossible to get it super tight. if the bit or shank has flats, then the chuck will have no issues.

I had same thing when I had Barley Crusher. I just used a file and flattened out the shaft more significantly so there was a better place for the chuck to grip. One thing I LOVE about my new monster mill..... the shaft is basically triangular with flattened sides.

What do u mean by slot? Your chuck can grab a perfectly cylindrical bout with no issue. Perhaps it's made to receive a manual handle? Either way, the drill Chuck shouldn't be slipping. you need to tighten that thing down better.

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Try wrapping a couple layers of electrical tape around the shaft. Torque your chuck down on it tight. Should give it something to grab onto.