Urgent

[tony]

Hi folks , im just in the middle of a job using Greenheart , which has 16mm bolts coming through it to hold it in place. Bearing in mind it then gets a washer + nut on & i will need a socket to tighten the nuts as they will be in a recess , which will then get plugged. My questions are ( i havent worked out a size for the socket yet ) can you get plug cutters with a big enough diameter for this , could you use something else , eg a holesaw . Really what would give the best finish , forgot to say the plugs will only need to be 35mm long or thereabouts. ps if its the plug cutter route , does anyone know a supplier, this is quite urgent so any advice would be much appreciated , thanks < Tony

 

[loftyhermes]

Tony,
I would suggest that when you have decided on the hole size have some lengths turned on a lathe to be a tight fit, hammer them into the hole and then just cut off and repeat.
Steve

 

[ColeyS1]

You can get big plug cutters but they aint cheap. I bought one from the bay years ago cause it was going cheap.Only after did I find out it was about 60-70 to buy new.
Edit: type in ' premium tenon plug cutter' on ebay

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[ColeyS1]

You'll need a nice big torquey pillar drill to cut them- especially in greenheart ! How many roughly are you gonna need ? If its only a few a bandsaw would probably do the job. Pretty sure those big type cutters aren't tapered, so if it's a I loose, you need to find a better sized drill bit

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[Graham Orm]

Here ya go.http://www.trend-uk.com/en/AT/product/INLAY_KIT_A/

No need for plugs, just cut a patch using this inlay kit on your router any size you choose and any shape.

 

[dm65]

Called a Dutchman on New Yankee Workshop

 

[tony]

Thanks everyone for the rapid replies , you have given me some good ideas . Coley , i need at least 42 plugs !

 

[oakfield]

Sometimes, when plugging old night latch holes in reclaimed doors I use a hole saw.

I have an off cut of MDF with various holes drilled in it. I then remove the pilot drill from the hole saw, clamp the MDF over the wood I will be cutting the plug from, lining up the correct size hole with a decent grain match and drill it out.

If you need a very tight fit, you can cut plugs slightly oversize and taper them on a belt sander.

 

[ColeyS1]

Thinking about it more I quite like your holesaw idea. Obviously you'd need to remove the centre drill bit. If you were to drill a load of holes to a 12mm ish piece of sheet material you could then screw this onto your greenheart. Atleast it would keep the holesaw in the right place and stop it from skidding off course. Has it gotta be bang on perfect here, or are we saying a bit of pu glue to fill any tiny holes will suffice ? Im intrigued now :ugeek:

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[Graham Orm]

Thinking about it more I quite like your holesaw idea. Obviously you'd need to remove the centre drill bit. If you were to drill a load of holes to a 12mm ish piece of sheet material you could then screw this onto your greenheart. Atleast it would keep the holesaw in the right place and stop it from skidding off course. Has it gotta be bang on perfect here, or are we saying a bit of pu glue to fill any tiny holes will suffice ? Im intrigued now :ugeek:

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I doubt you will get anywhere near the accuracy needed with a hole saw, they're not meant for precision work.

 

[Graham Orm]

Just behind the vice you can see patches in the bench top. These cover the bolt heads from the vice. They were made using the router with an inlay bit. they're about 20mm thick, as good as any plug and easier to make accurately. Of course with a round template you can make them look like a plug.

 

[tony]

Thanks again for further ideas , when i said 42 plugs its actually 42 pieces of timber with 3 holes in each , 126 plugs . I did attempt to turn some but it was a struggle to get the 4 prong drive embedded enough with it being so hard. The lathe im using at work is an old wadkin model , ive just been thrown in the deep end slightly as ive never been on these before, im a hobby turner & it should not be a problem to turn plugs as long as i can secure the workpiece sufficiently. By the way , this lathe seems to run very slowly even at top speed 2800RPM , can i assume the belt is stretched or something else & if it is stretched can it be shortened or will it need a new belt. Ive never worked with Greenheart before & ive been told it neeeds to be kept moist , is this correct , cheers for now, Tony

 

[ColeyS1]

Id seriously consider buying a cutter if there's that many to do. Id imagine it would save alot of hours not to mention accuracy/repeatability

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[tony]

Cutter ordered