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- 1). Obtain a high quality penetrating oil in a quart container. There are oils on the market that are made particularly for freeing up rusted metal parts. The cost may be in the $10 to $15 range, but it is well worth it over the cost of replacing the parts.
- 2). Pour approximately half a quart of the oil into a clean 1 lb. coffee can container. Place the can on the drill press table directly beneath the frozen drill chuck.
- 3). Raise the drill press table until the lubricant fully immerses the drill chuck in the oil.
- 4). Allow the drill chuck to set in the oil for 24 hours. This creates a bath of lubrication in and around the metal parts. The oil will migrate into the precision mating parts and "work" into the rust and corrosion.
- 5). Lower the drill press table and remove the oil container from the drill chuck. Allow the excess oil to drip from the chuck and wipe the chuck clean with the cloth rag. Remove the can of oil from the table and set it to the side.
- 6). Use the dead blow or rubber hammer and strike the chuck several times at the three, six, nine and 12 o'clock positions. Perform this several times to help loosen the metal parts. A dead blow or rubber hammer will not score or mar the metal surface of the drill chuck.
- 7). Place the drill chuck key into the chuck and attempt to move the drill chuck mechanism. You may want to gently strike the drill chuck a few times as you rotate the chuck key to open and close the drill bit holders. The chuck should be able to have some movement. If not, repeat the immersion process and keep soaking the frozen chuck.
- 8). Soak the chuck for additional 24 hours after you have freed the mechanism. Rotate the chuck with the key several times during the soaking process as described in Steps 5 and 6.
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