Why don't the plugs fit well?

[ron defino]

I'm testing out my new K4 kit and I noticed that the plugs do not fit in all the way to be at least somewhat flush.

I ended up cutting about 1/8 off the end that goes in first and now the plug fits almost flush. Just a little sanding is required now. 

I check and I have my jig set for 3/4, wood it 3/4 and I set the drill bit for 3/4. Odd it sticks out so far.

Any tricks out there for this?

Thanks

Ron

[james wilhelm]

Hi Ron , they are made that way ,  because of the different wood thickness  , and you have already learned the  trick , by cutting off  a little on the end that goes in the hole first , JIM  !!!

[ron defino]

Hi Jim. Thanks for the reply. That makes sense.

Thanks again 

[james wilhelm]

Ron , you are welcome , I do mine on my table belt sander , can do a box full in 10 minuties, glad I could help , JIM !!

[KregRep]

Kreg pocket-hole plugs are designed to work with wood from 3/4"- to 1-1/2"-thick. Because of this, it is possible that once the plug is inserted into your pocket hole, it will protrude past the workpiece surface. To eliminate any excess material and bring your plug to flush, we recommend using a flush-trimming saw or a flush-cut laminate bit in your router to trim off the majority of waste, and then sanding to flush.