| Project by kiefer | posted 275 days ago | 1845 views | 5 times favorited | 17 comments | ![]() |
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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 .
-- Kiefer 松
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17 comments so far
SPalm
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4108 posts in 2051 days
#1 posted 275 days ago
Well well, if that isn’t just darn right clever.
You get an A+ for ingenuity.
I like it,
Steve
-- -- I'm no rocket surgeon
jaykaypur
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2499 posts in 577 days
#2 posted 275 days ago
very well done.
-- Use it up, Wear it out --------------- Make it do, Or do without!
kiefer
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#3 posted 275 days ago
Thanks Steve
I could have cut the round tenons on the table saw,but this way I could make the plug in three steps moving from band saw cutting the round tenon to table saw cutting the top bevel to mitre saw cutting off the waste and back to the band saw .
-- Kiefer 松
SPalm
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4108 posts in 2051 days
#4 posted 275 days ago
I sensed that.
I could just imagine getting into it and flipping back and forth between machines with stop blocks and even the HDPE slide block. It is just dizzying to imagine what we efficiency freaks would be like after a count of 40.
-- -- I'm no rocket surgeon
StephenSchaad
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201 posts in 347 days
#5 posted 275 days ago
That’s AWESOME!
Jim Jakosh
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#6 posted 275 days ago
Neat idea! Great job on the jig and the end products!!..............Jim
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!!
Big_Eddy
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57 posts in 1051 days
#7 posted 275 days ago
I’d be interested in seeing a video if you have one.
-- If i'd a knowed you coulda goed I'd a seen you gotta went
rejo55
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149 posts in 411 days
#8 posted 275 days ago
Ain’t no way I’da ever thought about that. Man, that is thinking WAY outside the box!
I’m gonna write this down (if I ever need plugs for a timber frame).
Great job!!
Have a good’un
Joe
-- rejo55, East Texas If there were no trees, there wouldn't be much wood.
MonteCristo
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2060 posts in 357 days
#9 posted 275 days ago
Aside from you, Mork (of Mork and Mindy fame) is the only guy I know of that can make a square peg go into a round hole ! Very impressive !
-- Dwight - "Free legal advice available - contact Dewey, Cheetam & Howe""
Roger
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#10 posted 274 days ago
Very cleaver. I’m sure it works gr8
-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net
rance
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#11 posted 274 days ago
A very efficient system. Nice going.
-- Backer boards, stop blocks, build oversized, and never buy a hand plane--
Bertha
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13111 posts in 862 days
#12 posted 274 days ago
Genius with the socket!
-- My dad and I built a 65 chev pick up.I killed trannys in that thing for some reason-Hog
ccanderson102
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22 posts in 438 days
#13 posted 274 days ago
excellent innovative use of the tools!
horsch
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36 posts in 834 days
#14 posted 274 days ago
That is reeally cool. I just read an article on the Fine Woodworking website the other day on doing pretty much the same thing. Sorry, but you will need a Fine Woodworking online account to see it. This way does seem a bit easier, though. Both of these techniques would make Arts-And-Crafts/Greene and Greene Ebony plugs a lot easier. Thanks for sharing.
HillbillyShooter
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1361 posts in 461 days
#15 posted 274 days ago
Very ingenious, thanks for sharing.
-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington
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