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FORTY PLUGS FOR A FRIEND

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Project by kiefer posted 702 days ago 2331 views 5 times favorited 17 comments Add to Favorites Watch

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





17 comments so far

View SPalm's profile

SPalm

4739 posts in 2478 days


#1 posted 702 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

View jaykaypur's profile

jaykaypur

3251 posts in 1004 days


#2 posted 702 days ago

very well done.

-- Use it up, Wear it out --------------- Make it do, Or do without!

View kiefer's profile

kiefer

2941 posts in 1263 days


#3 posted 702 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

View SPalm's profile

SPalm

4739 posts in 2478 days


#4 posted 702 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

View StephenSchaad's profile

StephenSchaad

201 posts in 774 days


#5 posted 702 days ago

That’s AWESOME!

View Jim Jakosh's profile

Jim Jakosh

11049 posts in 1701 days


#6 posted 702 days ago

Neat idea! Great job on the jig and the end products!!..............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Big_Eddy's profile

Big_Eddy

57 posts in 1478 days


#7 posted 702 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

View rejo55's profile

rejo55

175 posts in 838 days


#8 posted 702 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

View MonteCristo's profile

MonteCristo

2094 posts in 784 days


#9 posted 702 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""

View Roger's profile

Roger

14094 posts in 1400 days


#10 posted 701 days ago

Very cleaver. I’m sure it works gr8

-- Roger from KY. Work/Play/Travel Safe. Kentuk55@bellsouth.net

View rance's profile

rance

4125 posts in 1756 days


#11 posted 701 days ago

A very efficient system. Nice going.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View Bertha's profile

Bertha

12951 posts in 1289 days


#12 posted 701 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

View ccanderson102's profile

ccanderson102

31 posts in 865 days


#13 posted 701 days ago

excellent innovative use of the tools!

View horsch's profile

horsch

40 posts in 1261 days


#14 posted 701 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.

View HillbillyShooter's profile

HillbillyShooter

4340 posts in 888 days


#15 posted 701 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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