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Project by kiefer posted 08-19-2012 11:55 PM 3082 views 7 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

17 comments so far

View SPalm's profile


5325 posts in 4082 days

#1 posted 08-20-2012 12:02 AM

Well well, if that isn’t just darn right clever.
You get an A+ for ingenuity.

I like it,

-- -- I'm no rocket surgeon

View jaykaypur's profile


4017 posts in 2608 days

#2 posted 08-20-2012 12:07 AM

very well done.

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

View kiefer's profile


5622 posts in 2867 days

#3 posted 08-20-2012 12:14 AM

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

View SPalm's profile


5325 posts in 4082 days

#4 posted 08-20-2012 12:26 AM

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


201 posts in 2378 days

#5 posted 08-20-2012 12:45 AM


View Jim Jakosh's profile

Jim Jakosh

21729 posts in 3305 days

#6 posted 08-20-2012 01:09 AM

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


57 posts in 3082 days

#7 posted 08-20-2012 01:16 AM

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


190 posts in 2442 days

#8 posted 08-20-2012 01:48 AM

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

-- rejo55, East Texas

View MonteCristo's profile


2099 posts in 2388 days

#9 posted 08-20-2012 03:16 AM

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


20952 posts in 3004 days

#10 posted 08-20-2012 12:21 PM

Very cleaver. I’m sure it works gr8

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

View rance's profile


4266 posts in 3360 days

#11 posted 08-20-2012 01:09 PM

A very efficient system. Nice going.

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

View Bertha's profile


13551 posts in 2893 days

#12 posted 08-20-2012 01:16 PM

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


34 posts in 2469 days

#13 posted 08-20-2012 01:58 PM

excellent innovative use of the tools!

View horsch's profile


42 posts in 2865 days

#14 posted 08-20-2012 03:06 PM

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


5811 posts in 2492 days

#15 posted 08-20-2012 03:35 PM

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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