Re: tapered plug - UPDATE

"todd" <toddrf@xxxxxxxxx> wrote in message
news:VuOdnWIOvbK7tBPbnZ2dnUVZ_uOmnZ2d@xxxxxxxxxxxxxx
While assembling a short handrail for a staircase, I drilled some 3/4"
holes with the Forstner to accept the head of the carriage bolts I used to
anchor the post to the staircase. Later, I purchased a 3/4" tapered plug
cutter so I could cut (what else) tapered plugs to cover up the
aforementioned holes. The problem I'm runnnig into is that the plug just
isn't big enough. I don't know if the plug cutter is cutting them
undersize of the Forstner is oversize, but the plug just isn't quite big
enough for an interference fit. Any ideas on remedying this situation?

todd

While pondering this today, the idea popped into my head that my 1" hole
saw, when used to cut a hole, would leave a waste piece of about 7/8"
diameter. I cut one and used a file to shape it down to be a bit tapered.
It was tedious, but it did the trick beautifully. However, I had three more
to make and didn't fancy filing them all down. So I cut three more plugs,
then chucked up the drum sander into the drill press. I just held the plugs
by hand and sanded around the outside to get a taper. This method also
worked fine and was much faster.

todd


.

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