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Kreg Pocket Hole Plugs Cutting Sled

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Project by steliart posted 383 days ago 2843 views 57 times favorited 22 comments Add to Favorites Watch

Kreg Pocket Hole Plugs Cutting Sled

Right,
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.

Enjoy

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 - http://www.steliart.com --





22 comments so far

View Drew - Rock-n H Woodshop's profile

Drew - Rock-n H Woodshop

633 posts in 1287 days


#1 posted 383 days ago

This rocks and talk about a money saver. Great ingenuity and thinking outside the box!

-- Drew -- "I cut it twice and it's still too short!"- Rock-n H Woodshop - Moore, OK

View steliart's profile

steliart

1807 posts in 1284 days


#2 posted 383 days ago

Thanks buddy.

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View Dallas's profile

Dallas

2854 posts in 1083 days


#3 posted 383 days ago

Interesting, but I’m not sure I would go to that much work.
To plug pocket holes that are visible I just stuff in a dowel and lop it off with a chisel then sand.

Am I missing something?

-- Improvise.... Adapt...... Overcome!

View MT_Stringer's profile

MT_Stringer

1797 posts in 1827 days


#4 posted 383 days ago

That’s a cool jig. Thanks for sharing.

-- Handcrafted by Mike Henderson - Channelview, Texas

View steliart's profile

steliart

1807 posts in 1284 days


#5 posted 383 days ago

Dallas, MT_Stringer,
Thanks for visiting and commenting :)

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View AngieO's profile

AngieO

1134 posts in 744 days


#6 posted 383 days ago

Good idea. Thanks for sharing.

View steliart's profile

steliart

1807 posts in 1284 days


#7 posted 383 days ago

Your welcome Angie
Thanks for visiting and comment

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View vanzemaljac's profile

vanzemaljac

265 posts in 2097 days


#8 posted 383 days ago

Practical tool, good idea, nice work …

-- Lathe and my imagination will do everything to realize my dreams...Vanzemaljac

View Joe Lyddon's profile

Joe Lyddon

7618 posts in 2649 days


#9 posted 383 days ago

Very interesting…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View steliart's profile

steliart

1807 posts in 1284 days


#10 posted 383 days ago

thanks guys

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View Straightbowed's profile

Straightbowed

717 posts in 894 days


#11 posted 383 days ago

yes indeedee

-- Stevo, work in tha city woodshop in the country

View violaine's profile

violaine

34 posts in 1418 days


#12 posted 382 days ago

please sell one to me!!! that prototype is just ok! LOL

thanks for sharing. great DIY!

View steliart's profile

steliart

1807 posts in 1284 days


#13 posted 382 days ago

violaine
The materials used are so expensive i wouldn’t know what to charge you hahaha

violaine & Straightbowed
Thanks for visiting and commenting

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View Dusty56's profile

Dusty56

11638 posts in 2284 days


#14 posted 382 days ago

Cool, how many plugs can you make in an hour ?

-- I'm absolutely positive that I couldn't be more uncertain!

View steliart's profile

steliart

1807 posts in 1284 days


#15 posted 382 days ago

Dusty56
How fast can you cut? ;) 100?

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

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