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Plugging screw joints

Using wooden plugs is a great way to conceal screws, and it's very simple to do with the right tools...

To make the plugs, you can use dowel or cut them yourself with plug cutters (See left) This is how i'm going to do it. You can buy them in many sizes, and they are made specifically for this purpose.
Start by drilling a piolot hole for the screw (This stops the wood splitting)
After the pilot hole is drilled, you need to make a recess for the screw and plug - called a counterbore. You can use a normal drill bit, spade bit or forestner bit - this drills accurate flat holes and is good for a job like this.
I mounted the drill bit above in my pillar drill to bore the hole. This is the best way because of it's accuracy - but you can do it with a regular drill.
After the counter bore had been drilled, I put the screw in.
To make the plug, again I mounted the cutter in the drill press and cut the plug. It's a good idea to take a loog at the grain on both pieces of wood, so that the plug will blend in when finished.
After the plug has been cut, pop it out using a screwdriver.
Using a mallet drive the plug into the counterbore - It's always a good idea to use a bit of glue to prevent the plug from coming out at a later time.
Using a SHARP chisel gradually remove the exess and pear it down to the surface.
Sand the surface lightly to remove any burr and clean it up.
Here is the finished plug - it looks much better than a screwhead, when the wood is finished it will blend in alot more.










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