Replies

1. 
   lat_axe | Dec 31, 2020 04:09am | #1

   Been there, done that! :-) Well, something like.

   I ended up sanding a smidgen from the plug after mounting it in the drill press chuck via the hole in the plug centre and a short length of threaded rod screwed into it.

   Careful (light) application of a sanding sponge to the spinning plug took off enough to get the plug in the hole .... although it then showed tiny gaps here and there around the circumference where the sanding wasn't even. Some aspects of the grain sand off easier than others, I suspect - even at a constant pressure of the sanding sponge against the spinning plug.

   I also tried to sand the plug more at it's bottom end than the top, to ensure it went down the hole easily but fitted well at the top, when flush.

   I haven't had to make such a large plug 'ole since but if I had a significant number to make, perhaps purchase of these matched pairs would be the proper solution:

   https://www.fine-tools.com/zapfenschneider.html

   As you will notice, they ain't inexpensive. However - no hole cutter drill bit hole in the middle and much cleaner edges to the auto-tapered plug.

   Lataxe

2. 
   john_c2 | Dec 31, 2020 04:54am | #2

   Its not cheap, but Lee Valley makes an excellent dowel maker that you can adjust the diameter up or down enough to get a perfect fit. Make the dowels in few foot lengths and cut them to your size.

1. 
   kudzupatch | Dec 31, 2020 06:00pm | #7

   I have a set of these and often make lengths of dowel stock. The problem is they leave a rather rough finish. Slow feed rates help but you are probably going to have a bit sanding in most cases. So the size might not be as consistent as you want.

3. 
   _mj_ | Dec 31, 2020 06:43am | #3

   You may ruin your holesaw, but my first thought was to alter the set of the inward facing teeth a touch. Use a flat punch and give a tap to every other inset tooth. It might could work maybe.

4. 
   bilyo | Dec 31, 2020 10:30am | #4

   It might help if you could be a bit more explicit about your project. However, have you seen these? The resulting plug, as mentioned above, is tapered so that when they are tapped into place they fit tightly with clean "no gap" edges.

   https://www.amazon.com/Snappy-1-Tapered-Plug-Cutter/dp/B001IHK7J8/ref=sr_1_1?dchild=1&keywords=1+plug+cutter&qid=1609428383&sr=8-1

   Of course, if the plug needs to be flush on both sides of the work piece, a tapered plug may not be the answer. I believe they also make non-tapered plug cutters. I don't know how precise they are or how tightly they would fit in a hole cut with the Forstner bit. But it should be easy enough to sand off a small amount.

   It might be easier and more precise to use a 3/4" dia. sanding drum in your drill press an lightly "kiss" the inside edge of the hole until the plug fits. Keep the work piece flat on the table as you do this in order to keep the edges perpendicular.

5. 
   weymouth2 | Dec 31, 2020 12:18pm | #5

   If you baked the pegs long enough, would there be shrinkage? This has the beauties of being cheap, mass-producible, and working theoretically :) I don’t know practically how much shrinkage one could expect out of a one inch plug, or what problems this might introduce post-shrinkage expansion. But it seems the simplest solution and therefore passes the KISS test.

1. 
   lat_axe | Dec 31, 2020 12:34pm | #6

   Wey,

   That's a good solution, especially as the glue on the dried plug would expand it again to make a good tight fit.

   Another option is to put the dried plug in with the grain running at right angles to that of the hole-bearing recipient, a la greenwood chair makers of post & rung chairs. The differential expansion would make a tight grip of plug in hole even without glue - although there might be slight gaps 90 degrees 'round the circumference from the tightest part of the join.

   Lataxe

2. 
   elmaduro | Jan 01, 2021 10:34pm | #9

   I'd start with this good baking solution and then also try setting the holesaw teeth idea. After that, maybe turn the pegs on a lathe?

6. 
   mikaol | Dec 31, 2020 08:25pm | #8

   soften the edge of the dowel with sandpaper making it round
   Mikaol