Sir;
There are a number of options available to you.
Some chucks were built to a standard for jaw fitting. You
might find a set of jaws that would fit. I would be sceptical of replacing only one, of trying to get near zero runout with one odd piece. Another option would be to acquire a (used) chuck and just replace the existing one. If possible, find the same chuck so you could share backing plates. Swapping inside to outside bodies would be cumbersome but doable. Even possibly using the jaws without changing the chuck body. That would be a matter of how close you came to finding the same chuck. These options would all be contingent on finding parts that would interchange. That
could get real expensive real fast and you might find yourself with a pile of unusable parts and still facing the original problem.
Now, to digress for a few and talk about chuck sizes. As far as "old iron" lathes go, the Atlas 10", any model, is considered a "light weight" as far as industrial machines go. There are many the same (M/L) size, the Atlas is toward the light end of that spectrum. My machine is a Craftsman 12(X36) which is basically the same machine on "riser blocks". An excellent machine for occasional "light" work, not so good for production work. It was acquired from a cotton mill in S. Carolina. Indirectly, but that was the original purchaser. Mine came with the same chuck as is on yours, but with "inside" gripping jaws. Chuck sizes go up from there, with "shipyard" and rolling mill lathes having chucks many
feet in diameter. Many such lathes have smaller chucks that fit the large ones with "blind" spindles. Small chucks for small work. . .
I have a couple of other lathes and mostly do model(H-O Trains) work. I sometimes get into other work repairing "stuff" and the occasional odd "big project". I have a Grizzly 9X, a mini 6X, and (used to have) a UniMat DB-200, basically a jeweler's lathe at (3") 75mm. The Grizzly G-1550 has the same spindle threads as the Craftsman(Atlas), 1-1/2X8, and I find myself more comfortable with the 4 inch chuck for personal reasons. Mostly because it was new and had low runout from the factory. I also have a 3 inch 3 jaw from the UniMat that I have "adapted" to the much larger machines. But to make such an adapter requires some advanced knowledge. But something I would
not recommend for a beginner. Not that I am an advanced machinist, I'm an electrical engineer. But hobby machining is necessary for other hobbies as well. I also have larger chucks, both an 8 inch and a 9 inch. Both 4 jaw independent and both very cumbersome (heavy) to deal with.
The bottom line here is that a smaller chuck is available, from the parts list for a
smaller machine. But lucking into one is about as rare as finding the odd jaw for your chuck. Most Chinese lathes are threaded for metric, M39X4.
Grizzly and
Jet are two I know of that (
in the past) did manufacture a lathe threaded for 1-1/2X8. I don't know if parts are still available, but it could be worth a try. Otherwise, I would recommend eBay or the like to acquire a replacement, looking for a 4 or 5 inch, with threaded back plate. A mini, some 3-1/2 inch diameter
is available. But that small doesn't use a backing plate like the bigger machines. They
could be fitted, with sufficient work, to a larger machine. I personally would recommend against it unless there was an over-riding need for such a small chuck.
Any larger on your machine would be asking for trouble. That would take some time at best, looking for something at a price you would pay might be even longer. What ever you end up doing, make sure a backing plate is included or
can be acquired for your spindle nose thread. At this point of your (assumed) knowledge, I would recommend against replacing a single jaw on your existing chuck. The wear, hence runout, could well be atrocious. Or possibly a drop in. If you do replace them, replace all three as a set. It is possible to grind to fit a single jaw, but that is something that requires a little more knowledge of your machine.
I find myself drifting into preaching or teaching mode so will back out for now. I will follow along anon and answer any question you have. But I've talked far too long now and will drop out.
Bill Hudson
.