"Dan-- I've found not all dowels are the same diameter in the bin. I drill a scrap & take it with me to make test fits. Not an every time answer to your problem but it works more often than not. Also I've never mic'ed a step drill…"
"I bought the Kreg. Simply because sometimes things just don't need to be complicated.
As for clamps Harbor Freight will see you the clamps with the round jaw pads. They aren't auto adjusting but then again once you set the clamp its set.…"
"Use your regular wood glue on all but a little bit of the plug. Use CA glue with accelerator on the last little bit. The CA will set almost instantly as you know helping to keep the plug from going in too deep."
"I'm certainly glad it all worked out for you in the end. You may have been into some softer wood on the other joint too. Either way you've got a nice bench that is ready to work for you. Nicely done."
"The 2 1/2" screws seem too long for attaching to the face of a 2x4. I would think that direction would only take a 2'' screw because the 2x4 is really 1 1/2" in that direction.
1 1/2" of wood plus the 1/2" (??)of…"
"I found a long time ago the best way to use the K5 is with a corded drill. If I have more than just 4-6 holes to drill I put the battery drill away. And that 20v Porter Cable with the 4amp battery is a hole drillin tool! The corded drill to me seems…"