In a moment of distraction I started the lathe with the chuck key in the chuck.
It was slow enough that the key didn't fall out and the square end pinged off when it the key hit the bed.
Don't think any damage has been done to the chuck at all, just some damage to my pride!
I'll order a new one, just want to make sure I get the right size, it seems just under half an inch square.
In the meantime I'll get a bit of square steel bar and machine up a temporary one tomorrow evening so we we don't have any more down time on the lathe than is necessary.
Apologies!