I am a registered (albeit infrequent) reader. The photos really help.
It turns out that MSC has steel jaws for about $21 each (76553791) and aluminum for $28 each (08637274). These have integral 0.500" keys machined right in, so location should be more precise.
I also need to see which sprocket on the chuck gives the best repeatability.
Joe Gwinn
I ended up buying a set (MSC # 01933480), and they fit tightly and work very well.
I did number the soft jaws 1..2..3 so I'll put them back on the chuck always the same way.
I recall you warming about the danger of getting clipped by the spinning big jaws. This is a real danger. I didn't get clipped, but there was a close call. That would have HURT. I may make a guard cover.
I would guess that pie jaws are safer.
Joe Gwinn
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