Making round-headed hole plugs; advice needed
Thanks in advance for any advice!
I am refinishing a number of danish-style teak dining chairs that use threaded fasteners whose holes are covered by wood plugs that have a round (concave) shaped head that protrudes slightly from the surface. Needles to say, the existing plugs are damaged in the process of removing them from the hole.
Because I can’t find replacements, I propose to make them myself. Plug cutters are not hard to find, but none of the ones I have found provide the round head I need. I imagine some 2-part process whereby I round the heads first using some type of drill-press mounted cutter which I have yet to identify, followed by actually cutting the plug, hopefully centered on the crown I produced in the first step. So…..
- Does such a crow-cutting tool exist?
- Does anybody have any other thoughts on how to create such a plug?
I’ve done my homework as best as I can, but I am coming up blank. BTW, the holes to plug seem to be between 13 & 14 mm in diameter (close to 17/32). Fuller makes 13 & 14 mm tapered cutters, so I guess I would buy the 14 mm cutter & use the thinnest part. any thoughts?
Thanks to all for your consideration!
Andy
Replies
can you turn?
I assume your plugs are inset not overlay.
For parts 1/2 inch +, I would turn them to fit and crown them on the lathe. You can also make a wood concave punch so that you don't damage the plugs on installation.
Fit does not have to be tight since I assume you will glue them in.
If no lathe, think about doing the same operation in a drill press using 3/4 inch dowels to start with. You will have to drill out each one to 1/2 inch to fit a 1/2 inch dowel in the drill press since yours probably will only take a 1/2 inch bit. Use a file and sandpaper to grind the 3/4 down to fit your chairs. DO NOT USE A SHARP INSTRUMENT LIKE A CHISEL SINCE THAT IS A LIFE-THREATENING OPERATION! The same file and sandpaper could crown each plug. I normally don't like to put lateral pressure on drill press bearings, but for a one-off I would try it. The hard way, but sometimes that is all we amateurs like me have.
Forrest
Thanks so much for your reply, I really appreciate it.!
No I don't have a lathe, but you've got me thinking about picking up a used one, maybe on Craiglsist. My FIL in Argentina makes his own shaper blades, & I am now thinking maybe I can do a similar thing to get a consistent crown. There might be up to 10 chairs with at least 6 plugs each, so whatever shortens the overall time is worth it.
You've also got me thinking about an alternative. The plugs are normally pressed in, which is why I didn't use the Home-Depot issue 1/2 generic "hardwood" crowned plugs. (A, they are not teak, and B, they would fall out). But if there was some way to glue them in such that they could be removed again later if need be without damaging the surrounding wood, then that might yet be a good option.
Thanks again for your help!
Andy
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