What is the best way to cut a perfect, circular plug of 2 - 3" diameter out of 3/4" stock??? I've not been too successful with a saber saw.
Jan 23, 2013, 12:39 PM
why, a hole saw. you are going to have to sand some burning off the edges, but those cores are pretty nice.
there will be a center hole of 1/4 though. you'll have to fill that with a section of dowel or plug cut with a plug cutter bit.This message has been edited. Last edited by: swschrad,
sig: if this is a new economy, how come they still want my old-fashioned money?
Jan 23, 2013, 03:48 PM
A hole saw would cut a good plug, but... I guess I wasn't clear that I need a 2" or 3" plug. A 2" hole saw cuts a 2" hole, unfortunately for me, not a 2" plug it's shy by 1/16 or 1/8". Unless there is an adjustable hole saw of some sort that cuts a plug, not just a hole. Know of anything like this? Thanks.
Jan 23, 2013, 04:59 PM
get a circle cutter (google it for what it looks like ) set the cutter so the it cuts with a flat side on the cut out plug. If you clamp the wood to a backer board SECURELY, repeat, SECURELY, run your drill press at a low speed you should be able to do it without a pilot drill, otherwise you will have a center hole to fill
Jan 23, 2013, 08:13 PM
You can get hole saws in 1/8 increments. Also, 2-1/8 Is one of the most common sizes as it's used to make the hole for doorknobs. A 2-1/8" hole saw will make a 2" plug.
You can get around the hole in the middle in several ways:
1. Use a drill press and clamp your stock. 2. Set the pilot bit very shallow so that it is protruding just past the teeth of the hole saw. Start drilling until the hole saw cuts in about 1/8". Remove the pilot bit and let the hole saw guide itself - but be careful as it will be easier to bind and jump out.
Jan 24, 2013, 03:49 AM
Thanks! Great info. Didn't realize there was such a selection. Appreciate your info.