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I hope what ever was in the chuck was A light and B not expensive! Youll get it fixed....
So did you make it a low engagement thread form? Ie did you make the minor diameter of the other part bigger, to allow for the shallower thread depth on the adaptor ? I have been seeing lately what are also called modified thread forms. So the thread pitch is still the same and so is the OD still the same and the effective thread diameter is still the same, but the difference is just the minor diameter of the tread is way larger. In some cases it is about 1/2 the depth. When I have to make these, I take the standard full form insert, then just shorten the front of the insert to get the radial depth correct when the full form on the outside makes the correct diameter. So when thread cutting, leave the OD larger by 0.1 to 0.2 mm on diameter, and bring it down to the nominal size or the target size. The internal threads are just done with the standard internal insert, or the standard tap for that thread size is used, but the minor diameter is bored larger accordingly. I am not sure how widely used the modified thread form is used, but for blowpin bodies or areas where a standard thread form does not leave enough remaining wall section, that is what we do. Neil