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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906 posts in 561 days
posted 427 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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418 posts in 700 days
posted 427 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 593 days
posted 426 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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3035 posts in 914 days
posted 426 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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7894 posts in 660 days
posted 426 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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278 posts in 688 days
posted 426 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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381 posts in 1020 days
posted 426 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, a family tradition. (No PM's - auto-deleted.) - "I am a seeker, not a follower."
Napaman
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3482 posts in 970 days
posted 426 days ago
its coming along great!!!!!!
-- Matt, Napa, CA...fun is beautiful...just trying to have some fun...
jcees
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552 posts in 692 days
posted 425 days ago
Schwweeeeeeet!!!
always,
J.C.
-- "Imagination is more important than knowledge" -- Albert Einstein
Karson
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25793 posts in 1293 days
posted 425 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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2748 posts in 767 days
posted 425 days ago
Great photos of an interesting process.
-- Check out my new website! http://www.blakeweberwoodworking.com
ChicoWoodnut
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895 posts in 708 days
posted 424 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