Replies

1. 
   user-450633 | Dec 02, 2004 04:03am | #1

   In the future use edge spur countersink for proper cutting action and sizing. Also a big secret: use machine ship counterbores with interchangeable pilots as the ycan be used after pilot hole and make an impeccable hole for any size screw or bolt

   I am not at cross ref chart but check also for metric cutters too.

   Check Veritas(Lee Valley)(tapered), Fuller manufacturing /woodworkerssupply(tapered)/ Morris Tool

   In a pinch only: get closest size under and have machine shop grind id to size or have them dress cylindrical stone and very carefully do it on a drill press jig yourself(ie plug cutter in chuck and stone mounted in machinists vise.

   Make sure plug does not touch screw as movement over time will telegraph plug.

2. 
   cowtown | Feb 12, 2005 06:03am | #2

   i dunno how many plugs you need to cut, but if it's only a few, you could make yer own plug cutter.

   find a piece of steel shaft, maybe 3/8 or 1/2" in diameter and 4" long, and drill a 9/32 hole about 3/4 of the length.

   Chuck it in yer drill press and use a file to grind a bevel on the front edge so that it looks like a leather punch.

   Then, take yer hacksaw and cut a notch into the bevel , so that it becomes like a single saw tooth. This will cut the plug, and then you gotta worry about clearing the chips too. yer single saw tooth has to be able to do that.

   Now, you got two options to choose from,

   1)
   You can take yer hacksaw and cut into the core of yer newly made tool about 5/8" above the bevel, and also at an inch and a half above it, and remove half the tube, in order to create an opening not dissimalar to the breech of a rifle. This will let you clear any jammed plugs or just keep on ejecting them.

   2)
   Or you can use the cutter as is, just cut 2/3 of the way through 3/4" scrap and then back the cutter out. when you got enuf plugs cut, you slather the top of yer plugs with duct tape, and then resaw the scrap on the bandsaw so that it releases the plugs.

   I know you can't see what I'm describing but if you visualize it's shape almost like one of the VA plug cutters, you should get the drift.

   Option one is more work, but if a plug breaks off as yer cutting it, you can just keep on going. With option 2, if a plug breaks off when yer cutting it, you may have to unchuck the cutter, and use a 1/4" drill to remove the offending piece.

   I'd possibly start with option 2, and if it's too much of a PITA, then you can still go for option one.

   that's if you wanna make work for yourself.

   Or, you could just back the screws out, take a cutter which cuts a 3/8 counterbore, set the drill bit for a shallower depth of screw hole than you've used, just enuf to keep it guided, rebore the hole, so that normal 3/8 plugs fit, and go on from there.

   You've probably solved yer dillemma by now, but it was an interesting one.

   Eric
   in Cowtown

3. 
   highfigh | Feb 12, 2005 07:59am | #3

   I assume that your plug cutter set doesn't include anything to make tapered plugs, eh? That would work.

   "I cut this piece four times and it's still too short."