Introduction: Repair Poor Design of Ryobi Chuck Key Holder With Sugru
The Ryobi drill press at my local hackerspace has a built in chuck key holder that doesn't do its job very well. The drill press vibrates sometimes and then the chuck key falls out of the holder.
The second picture show the design flaw of the holder. There is a lip on one side, but none on the other. We are going to fix this with Sugru.
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Step 1: Cut Off Small Piece of Sugru
Due to the size of the chuck key holder we don't need much Sugru. I cut off a small piece for this project.
Step 2: Knead Sugru to Match Width of Chuck Key Holder
Knead the sliver of Sugru to match the width of the holder.
Step 3: Fold Sugru Over Hold to Form New Lip
Take the sliver of Sugru and fold it over the end of the edge with no lip to form a new lip. The Sugru will set and form an excellent bond with the plastic.
Step 4: Finished Product
This is what it looks like after it has dried. Notice now that the opening on the holder (with the new lip) is smaller than the width of the main part of the chuck key. No more falling out of the holder.
The second picture show the newly improved chuck key holder mounted on the drill press.