Introduction: Modern 3-Jaw Chuck on Stanley Hand Brace

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About: I've been an IT guy for all my working life, but love to tinker in the shed as a hobby. Kids and wife always breaking stuff so I got pretty good at fixing stuff. I try to learn a new skill every year and have …

With the rise of the interest in hand-tool woodworking and the passage of time finding auger bits for your Hand Brace that are in decent condition isn't always possible. The modern hex-shank auger bits simply don't work correctly in the old two-jaw chucks. Sure it's possible to buy some fancy new brace that's going to be expensive and lacking the charm of the old school braces.

So, let's upgrade an old Stanley Hand Brace with a modern 3-jaw chuck and get access to all those new shiny auger bits.

Supplies

Supplies

  • Old Hand Brace, I prefer the Stanley ones.
  • These are cheap and easy to pick up at second-hand shops, flea markets etc...
  • Drill Shank of your choice
  • I used a C12 to B16 Shank from AilExpress
  • https://www.aliexpress.us/item/3256801824401498.html?spm=a2g0o.order_detail.order_detail_item.3.1538f19cBTHmwv&gatewayAdapt=glo2usa4itemAdapt
  • Drill Chuck of your choice
  • I used a 13mm B16 Chuck, it's a bit heavy so I should change it out to a 10mm B16 at some stage.
  • https://www.aliexpress.us/item/1005001971160009.html?spm=a2g0o.order_detail.order_detail_item.5.1538f19cBTHmwv&gatewayAdapt=glo2usa
  • Brass Bushing
  • I got a used a 12x18x10-24x3mm
  • https://www.aliexpress.us/item/1005004265918464.html?spm=a2g0o.order_list.order_list_main.387.5ae41802dZDgGz&gatewayAdapt=glo2usa


Tools

  • 12mm drill bit
  • Small drill bit (the size of the pin you will drive out later)
  • Drill
  • Hacksaw or angle grinder with cut-off disk
  • Pin Punch
  • Centre Punch
  • Small hammer
  • Sand Paper or file.
  • Wire brush

Step 1: Optional

While not required I do recommend that you take the time to clean and restore your Brace to its former glory. This is however out of the scope of this instructable.

Step 2: Disassembly

Unscrew the chuck from the Brace, you should be able to find the small pin securing the gear to the shaft. This is how the Stanley Braces are made anyway, but this can vary. You may need to clean up the gear with a wire brush to find the pin. Now drive the pin out using the punch and hammer.

Step 3: Fit the Parts

On a Stanley Brace, the shaft is just over 11mm in diameter. Now unless you are lucky enough to have a lathe it's easier to drill the Brace out to the diameter of the new shaft rather than turn the shaft down on your non-existent lathe.

The shaft I purchased was 12mm in diameter so I carefully drilled the brace and gear out to this size.

You can now test fit the shaft into the Brace, make sure to insert the brass bushing so it takes the load when applying force onto the Brace.

The shaft is most likely too long and will need to be cut to length, mark the shaft and trim to length. Now sand, file, and polish the cut until it's smooth and flush with the Brace.

Now while test fitting the shaft in the brace mark the shaft where the pin goes through the gear. Centre punch the shaft and carefully drill a hole through the shaft so the pin fits in tightly. You can now fully assemble the brace, be careful to make sure the pin aligns with the gear teeth.

Step 4: Stick the Chuck on the Shaft

You can now tap the new chuck onto the shaft and your Brace is ready to take modern drill bits. As I mentioned at the start a 13mm chuck is really a bit too big and heavy and I should have bought the 10mm one as this will still fit the large hex shanks of modern auger bits.

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