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Forum topic by wdkits1 posted 08-22-2009 04:29 PM 12138 views 4 times favorited 8 replies Add to Favorites Watch
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wdkits1

212 posts in 2020 days


08-22-2009 04:29 PM

Hi everyone
l love using pocket hole screws. They are quick, easy to use and make a strong connection. The down side is that you normally can’t use them for exposed work mostly because they are kind of ugly.
Well on the latest project that I’m working on (custom closets) there are a few places that I have to use them in an exposed area so I had to figure out a way to make plugs (out of Jatoba) to fill in those ugly holes. Here is what I came up with.
I start by turning a 3/8” dowel out of 1/2” scrap. I use a 3/8” open end wrench as a reference to get the dowel to uniform size.

Next step is to drill a pocket hole (with Kreg Jig) in a scrap piece of wood and insert a screw( to drive out the cut plug).

Insert the dowel into the pocket hole until it bottoms out against the screw head.

Set the fence on the bandsaw to just clear the edge of the dowel jig and saw off the dowel.

I use a belt sander to sand the plug flush with the jig and pop it out with the exposed screw.

Here is the installed plug in place on the bottom shelf of the cabinet.

Hope some of you can use this little tid-bit of info.

-- Mike --http://www.custommade.com/by/mikemathieu/


8 replies so far

View a1Jim's profile

a1Jim

112174 posts in 2244 days


#1 posted 08-22-2009 04:40 PM

Hey Mike
Thanks for sharing,cool idea.

-- http://artisticwoodstudio.com Custom furniture

View Scott Bryan's profile

Scott Bryan

27251 posts in 2489 days


#2 posted 08-22-2009 06:47 PM

Mike, that is a novel approach. I know that you can buy the plugs but they are limited as far as the wood species goes. Like you I enjoy using pocket screws, especially in cabinet construction but have never used them on the exposed faces simply due to the problem that you described. This approach certainly gives me something to consider.

Thanks for the post.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

View Karson's profile

Karson

34878 posts in 3068 days


#3 posted 08-22-2009 06:54 PM

I bought a bit that goes in my drill press and it cuts plugs from what ever wood you want. I think it was Rockler that made it. I’ve never used it yet. (now I need to go and find it)

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View Chris Wright's profile

Chris Wright

529 posts in 2148 days


#4 posted 08-22-2009 07:15 PM

Here’s a nice plug cutter that you can use to cut plugs at an angle and really conceal the holes.

http://woodworker.com/cgi-bin/FULLPRES.exe?PARTNUM=151-439

-- "At its best, life is completely unpredictable." - Christopher Walken

View hObOmOnk's profile

hObOmOnk

1381 posts in 2795 days


#5 posted 08-22-2009 08:49 PM

A Japanese Flush Cut saw also works.

Lee Valley

-- 温故知新

View Joe Weaver's profile

Joe Weaver

404 posts in 2353 days


#6 posted 08-22-2009 09:20 PM

I got a tenon cutter 3/8 from mlcs and make all my own plugs.
http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/plgtenon.html

-- Joe, Ga

View spanky46's profile

spanky46

977 posts in 2057 days


#7 posted 08-22-2009 10:36 PM

Great ingenuity Mike! Thanks for sharing.

-- spanky46 -- Never enough clamps...Never enough tools...Never enough time.

View wdkits1's profile

wdkits1

212 posts in 2020 days


#8 posted 08-22-2009 10:43 PM

That is what I find fun about woodworking .Making chicken salad out of chicken s—t. LOL

-- Mike --http://www.custommade.com/by/mikemathieu/

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