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