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2" FACE grain Poplar Plug or 2" Plug Cutter Needed

6/22/13       
Dave

Website: http://davescustomservices.com

I am looking for a 2" diameter face grain wood plug made from Poplar, Birch, or soft maple. I was using 2" dowell but it turns to dark when finished for what I am doing. I bought a 2" plug cutter from Lee Valley, junk. I could not get it to cut more than 2 plugs from poplar at 200 RPM it siezes up in the wood and about starts a fire. I would also be interested in a good quality 2" plug cutter but it might be more economical to just buy the plugs. I need about 100 plugs now, more later.

6/22/13       #2: 2" FACE grain Poplar Plug or 2 ...
mark

No great source off the top of my head, but you could try a local turning company. These folks are near me (click on link below).

Or just use a hole saw on the drill press with the pilot bit removed; not tapered, but neither were the dowels.

Osborne Wood

6/23/13       #3: 2" FACE grain Poplar Plug or 2 ...
David R Sochar Member

Website: http://www.acornwoodworks.com

Doesn't anyone use a lathe anymore?

Glue up the stock for 'thickness' so you have long grain running from center to center, mount and turn. Slice the 2" cylinder on the bandsaw or tablesaw for length/thickness. You want taper? Then taper them on the lathe while turning.

If it took me more than an 2 hours to make 100 plugs (labor selling price = $.75 each), I'd go sell insurance.

6/24/13       #4: 2" FACE grain Poplar Plug or 2 ...
mark

On the plus side: all those folks turning short grain dowels could use some insurance.

6/25/13       #5: 2" FACE grain Poplar Plug or 2 ...
scott

Assuming you have no lathe, why not make a template for a plunge router and cut the little circles and then either cut them out with the bandsaw or onion skin them and wide belt off the back side? No bevel but your template can be custom sized to your hole cutter or whatever.

6/25/13       #6: 2" FACE grain Poplar Plug or 2 ...
Dave

All good advice. Thank you. I thought I would just be able to buy 2" face grain plugs. No luck. I may come up with a system to make them. If any one has made more than 100 of these let me know the best way. Or I will settle for 1-1/2" diameter which I am finding available.

6/25/13       #7: 2" FACE grain Poplar Plug or 2 ...
Dave

Website: http://davescustomservices.com

UPDATE! I was just getting ready to send this 2" plug cutter back to Lee Valley when I decided to try it again. This time, instead of trying to drill 1 plug all the way through, I drilled a bunch of shallow plugs in a row, about 10, all right next to each other so that the "kerf" of the plug cutter overlapped the kerf of the next plug, so I ended up with 2 relief points on each side of the plug as I drilled, (3 relief points for the next row if positioned right) then just took about a 1/16-1/8" bite on each one going back and doing this on the whole row, wala, 10 nice 2" diameter face grain Poplar plugs at what ever thickness I need. Now just got do the rest. Ran about 390 RPM, let the bit cool down after each row, really works well now. As usual, it was me not knowing what I'm doing...


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