|Project by steliart||posted 07-05-2013 04:04 PM||5753 views||63 times favorited||22 comments|
Kreg Pocket Hole Plugs Cutting Sled
I did a Kreg Jig Work Platform, and I even found an alternative to the Pocket Hole Screws, I think is about time to complete the set with a Kreg Pocket Hole Plugs Cutting Sled.
It’s more like a dowel cutting sled that you make two different cuts with it, and end-up with the Pocket Hole Plugs.
For the sled base 48cmX33cm (19X13”) and fence (4cm/1½ high) I used ¾ marine plywood joint with glue and biscuits.
Then I set my Table saw fence to 30cm (12”) and made the first cut with the sled fence running on the TS sled. (Do NOT move the TS fence)
Using a protractor I drew a line at 15 degrees from the sled base to the left side to give me the angle cut of the plug.
Setting my miter gauge to 30 degrees I made the second cut to the base. (Keep those gauge settings)
I sand down to 10mm (3/8”) few piece of MDF about 5cm (2”) width to be used as the dowels guides.
one piece I glued and nailed on the line we drew before, then I used a 10mm 3/8” dowel as spacer and glue the second piece, and since my TS has not moved I cut them flash to the sleds left side. The using my miter gauge again I cut flush the bottom overhanging piece.
With my Table Saw fence still in place I turn the sled and use the 30 degrees angle cut bottom to run on the TS fence and with a blade height to 4cm (1½”) I cut through the sled fence and base creating a pathway about 10cm (4”) deep.
Using a dowel as spacer I glued and nailed another piece of MDF to be use as a guide for the cross cutting the plug, and then pass the sled one more time to cut the MDF guide (this step could be skipped and done at the same time with the previous one).
A counter sink T-nut at the back of the sled’s fence, and a bolt with washer, will be used for the stop block which has an adjustable groove and same height with the fence.
Next on the photos you will see the first test, rip and cross cut of a dowel.
The result was successful and here is the comparison an original Kreg Plug with the shop-made one, same length, and same angle cuts.
If you find that your dowels are very tight fit or need some sanding, try putting them in the microwave on a paper towel on high temperature for 30 seconds, this will shrink the dowel down to size. Make sure you check also the plug’s length, you might need to adjust the stop block also… experiment a bit to get it right.
Finally, I screwed a push block at an angle on the sled, to help pushing and holding it in place.
Thanks for reading and commenting
Stelios L.A. Stavrinides
-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions