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Make it out of cardboard. If you can’t make it out of cardboard first, you won’t be able to make it out of metal.

Think about how easy it is to cut and shape cardboard. And if you screw up, it’s only cardboard.

It works!

Princess Auto has a keyless chuck to turn your 3/8″ drill into a 1/2″ drill. Around $15 CDN as of this writing. Seems to work dandy, and the Hitachi lives to fight another day.

Why yes, they DO come off.

It took quite a bit of abuse to do so, probably made worse by trying to cut a 2-3/4″ hole in steel.  The chatter exploded the original chuck.