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Is their any quick way to measure the plugs so they fit flush without alot of sanding? Or is their a jig or easy way to cut the plugs?

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Thanks for the info

James Waller said:
Most will use a Japanese flush cut saw to saw off most of the plug and then sand it down.
Like James said the flush cut saw or cut a small amount off the round end so it runs deeper in cut.
i just use a belt sander (porter cable 2 1/4") with some 100 or 120 grit.takes it down pretty quick
In a pinch I have cut my own using a bandsaw.

I drilled a series of pocket holes in the face of a 1x6. I then drilled out a 1/8" hole through each pocket hole. I cut some 3/8" dowel and drove them into the holes. I then set up the fence on my bandsaw and using a resaw-type operation, I fed the wood through. Then I popped the plugs out with a nail. They didn't require a lot of sanding, but from a time-management standpoint, the store-bought are a lot easier.
Look for my video and make your own plugs

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