|Project by kiefer||posted 08-19-2012 11:55 PM||2765 views||7 times favorited||17 comments|
Needed some plugs to finish screw holes in timber framing at a friends house .
He wanted square plugs to fit into the 5/8” holes so here is how I made them using a simple jig on my band saw to form the round portion which I can size very accurately with the adjustable blade guide on the jig (pic2).
I cut a length of maple and slightly planed the corners to fit into the drilled opening of the jig ,the maple blank is spun by a cordless drill with a socket slipped over the blank and slowly fed into the running band saw blade.
This forms a round tenon and the length is determined by a stop behind the jig clamped to the table .
From here I take the blank to the table saw and cut the square part of the plug at a 10 DEG. angle and leaving a 1/8” centre section which is easily broken off and sanded finished .
Pic 6 shows the jig I use for this cut .
Pic 1 shows the installation tool I made from one of the leftovers ,just cleaned out the centre and it drives the plugs in without damage to the finish .