I spent some time today setting the ebony plugs I made in my last entry. It was pretty easy really even though I was pretty apprehensive about drilling holes in an assembled piece.
Start by drilling some holes. These plugs are 1/4” so the drill bit is a little smaller at 3/16”. I drilled a little over the depth of the plugs at 1/4”
I bought a very cheap 1/4” hollow mortice chisel. I flipped the bit upside down and used it to center the chisel over the holes.
Then I squared the bit.
I drove it home with a wooden mallet. I take two passes at this. The idea is to keep the sides well defined. When you pull the hollow chisel out you don’t want to rock it. Pull it STRAIGHT OUT. That keeps the hole from enlarging or deforming.
Here is what I was left with. Clean up the bottom a little with a small chisel. I used a 1/8” because I don’t want to meddle wth the definition of the square hole or crush the sides.
Dab a little glue in the hole to coat the sides. No glue on the plugs. I don’t want any squeeze out.
Chamfer the plug just a little starting about 1/16” from the bottom. Don’t start the taper up too high, you only need a little bit to get it started. Press the plug in with your finger.
Tap it in with a small mallet till the edges are JUST FLUSH with the face. The effect is that the plug is proud because of the pillow, not because it is sticking out of the hole.
As you can see, these are not perfect. For my first run I put the plugs on the back of the case. I think the bottom plug should be a little further to the right to separate them a little more. Also, they are not perfectly squarely aligned. Ah well, it is a good start and I have the process worked out.
-- Scott - Chico California http://chicowoodnut.home.comcast.net
12 comments so far
3fingerpat
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888 posts in 546 days
posted 413 days ago
Scott, I have really enjoyed your series on this Night Stand, it shows great promise, planning and execution on your part, well done so far, keep up the good work!
-- "You get what you inspect, not what you expect"
bfd
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413 posts in 686 days
posted 413 days ago
Scott,
These look fantastic! Great detail in the blog and in your work. I am excited to try this in my table. You must be in the home stretch now on your night stands.
-- Brian, Folsom, CA http://www.brianfullerdesigns.com
Texasgaloot
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467 posts in 579 days
posted 412 days ago
This is a great series.
Clever approach using the hollow mortise chisel! Well done. I’m Greene with envy.
-- There's no tool like an old tool...
Bob #2
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2991 posts in 900 days
posted 412 days ago
You really do nice work Scott.
Your joints are almst invisible.
Bob
-- A mind, like a home, is furnished by its owner
trifern
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7890 posts in 646 days
posted 412 days ago
That is a wonderful detail. Thanks for sharing.
-- My favorite piece is my last one, my best piece is my next one.
stanley2
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274 posts in 674 days
posted 412 days ago
Scott – look’n good. Isn’t it fun lining up those little devils with no way to see because of all the fingers holding the hollow chisel. Are you going to Pasadena in Oct?
-- Phil in British Columbia
drgoodwood
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372 posts in 1006 days
posted 412 days ago
Hi Scott:
I like your idea of offsetting the second peg.
Tip: I would use some blue painters tape in the area you wish to drill/punch.
Carefully layout pencil lines for alignment of where you want to cut.
You can drill and punch directly through the tape.
I’m planning to use some square pegs in an upcoming design.
I’ve decided to align the pegs diagonally for a little extra effect.
-- Randy, Rustic Artisan (sixth generation) - "I am a seeker, not a follower."
Napaman
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3421 posts in 956 days
posted 412 days ago
its coming along great!!!!!!
-- Matt, Napa, CA...fun is beautiful...just trying to have some fun...
jcees
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548 posts in 678 days
posted 411 days ago
Schwweeeeeeet!!!
always,
J.C.
-- "Imagination is more important than knowledge" -- Albert Einstein
Karson
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25279 posts in 1279 days
posted 411 days ago
Great job. Looking nice.
Here is my blog on my G&G kitchen cabinets.
I put my pegs 5/8 from each side Top right is 5/8 – 5/8 and the others are 5/8 from the where the cross pieces met.
I just guessed at the placement. I thought it looked balanced. I used 3/8” plugs
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
Blake
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2715 posts in 753 days
posted 411 days ago
Great photos of an interesting process.
-- Check out my new website! http://www.blakeweberwoodworking.com
ChicoWoodnut
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894 posts in 694 days
posted 410 days ago
Phil: Lining up those little devils is indeed a challenge. I’m getting pretty good at it though. This whole project has been a long series of firsts for me.
Randy: Thanks. The blue tape idea sounds excellent. Aligning the pegs like that isn’t my idea. It was invented by Henry and Charles Greene in about 1904 LOL.
Karson: Thanks for the peek at those kitchen cabinets. The way you constructed the doors is inspiring. I have a tall case that has doors I wish I had built like that. (They warped and don’t quite sit flush where they meet in the middle).
Blake: Thanks! Did you get your pin router thing worked out?
Thanks to all who have looked.
-- Scott - Chico California http://chicowoodnut.home.comcast.net