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Outdoor Morris Chair #4: Fine tuning wood plugs

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Blog entry by LegendInMyOwnMind posted 05-01-2011 05:35 PM 1559 reads 0 times favorited 3 comments Add to Favorites Watch
« Part 3: First leg done... Playing with jigs Part 4 of Outdoor Morris Chair series Part 5: Really stupid mistake »

I’m sure someone out there really knows how to do this right, but I really struggle with wood plugs. If I use the standard countersink bit it really tears apart the wood.

That’s where a forstner bit really comes in handy. I can start a cut and get really clean edges.

The next step that I really have a hard time with is a collared drill bit. Seems like I never can get the collar at just the right place.

It takes me some trial and error to finally get a clean plug. Only mar is the collar indent where I pushed too hard. Incidentally, that was probably the best hole I made.

Now to figure out how to not end up with hammer marks where I pounded in the wood plug! Maybe if I use a block of hardwood between the hammer and the plug?

-- Doug - When all you own is a hammer, everything looks like a nail.



3 comments so far

View Div's profile

Div

1653 posts in 1689 days


#1 posted 05-01-2011 08:10 PM

Doug, check out this I’m sure you will find some handy info in the posting. It looks like you might be using dowelling for plugs. Buy yourself a plug cutter and make your own. They are not expensive. Don’t hammer in all the way. Leave a little proud and sand flush. Good luck!

-- Div @ the bottom end of Africa. "A woodworker's sharpest tool should be his mind."

View Jamie Speirs's profile

Jamie Speirs

4163 posts in 1605 days


#2 posted 05-01-2011 08:18 PM

http://www.axminster.co.uk/axminster-combined-drill-and-countersinks-with-hex-shanks-tct-prod816426/

-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View Will Stokes's profile

Will Stokes

264 posts in 2103 days


#3 posted 05-01-2011 08:54 PM

Yeah, use a plug cutter to cut your plugs from the same wood you’re putting them into. I’m sure you have some scraps around and this is a great way to use them. Or, if you prefer, use contrasting plugs out of a different species. Next, when hammering in the plug make sure the grain is aligned with the grain of the wood. If the grain direction matches it will look much better and almost disappear. As Div says, leave it prowd, then sand it plug. I usually just use my random orbital sander, although in the future I might try using a block plane to knock it down most of the way. I always glue my plugs in place as I don’t want them coming out. I’d buy a nice set of plug cutters of various sizes. They are cheap. Check out grizzly’s or Harbor freights selection. I have two plug cutters someone gave me, not a complete set, some day I’ll splurge, maybe even get tapered plug cutters, we’ll see. :-) As you saw, use the forstner bit to drill the holes. I don’t even have a stop collar. Instead, use a drill press with a depth stop. A cheap bench-top drill press (~$99) can work wonders. I love mine, it’s just a cheap Skil but it gets the job done. Hopefully this all helps. :)

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