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I've just started to notice that many of the plugs I try to insert into the pocket holes do not want to slide in freely as they did once. Anyone know of a reason this might be happening? With wear does the drill bit get narrower?

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I use a bandsaw to take off some of the end of the plug, but I use pliers to hold the plug as I am sawing.

Andrew Pensavalle said:
Dave,

See my topic "using the Kreg plugs". I found out that the plugs come in one length and that length is to allow them to be use in 2 x 4 lumber. If you are using anything like the normal 3/4" lumber, you have to lop off about 3/16 to 1/4 inch off the blunt end or be prepared to use a chisel or a lot of sanding. I found the easiest way for me was to use my stationary scroll saw to do the trimming. Watch the fingers......LOL. Another down side is that you might not be able to find plugs in matching wood or wood that will stain up the same as your project wood. However if your plugs are placed well, it can add an appealing look to your project. I don't think that Kreg offers it, but there are commercially available plug cutter jigs for pocket holes if you plan to do a lot of pocket hole joinery or if you want to guarntee that your plugs are from the same wood as you are using.

I hope the added information helps.

Andy
I find this especially when using oak plugs.
Me too, Rod



Rod said:
I find this especially when using oak plugs.
I just made a table to set my 12 bottle wine cooler on. There were six pocket holes that would have been visible on the inside, so I decided to plug them with paint-grade Kreg plugs. Since there wasn't enough clearance for my router, I used my father's Bosch "Finecut" flush cut power handsaw to remove the extra, then sanded with course, then fine grit. It worked out great! I have primed and painted the table, but I need to sand and apply a second coat. I'll post pictures when I'm finished.
Be careful to store your plugs airtight, perhaps in zipper freezer bags with the air pushed out. Can help kep them right-sized...
I can't locate it now, but someone came up with the idea of putting them into the microwave for a few seconds. I tried it with the particular plugs that would not go in and the slid in without effort just as if they had not swelled.from moisture. Regarding the plug cutter jig. I believe they are available from Woodcraft. You can do a google search and you should be able to get a hit. I don't know if you people at Kreg want us to talk about that since that means that we would not be purchasing the precut plugs.

Michael Hritz said:
Be careful to store your plugs airtight, perhaps in zipper freezer bags with the air pushed out. Can help kep them right-sized...
I have found that the microwave method is far less effective for the plastic plugs.

[joking]
Have u tryed a new drill bit.... it did it to me once..
When it was happening to me, the drill bit was new and during the same run, some plugs would fit and others would not.



Mitesh Makan said:
Have u tryed a new drill bit.... it did it to me once..
What I have one is drill just a shade deeper for screw and it fits real nice ,Just a little bit of sanding
I found the quickest and easiest way to trim the plugs for 3/4" stock was use a vise grip and then "touch" the plug at the correct angle to the belt sander. It was pretty fast and efficient. Maintaining the correct angle was the tricky part but after 3 or 4 it was easy.

Brian Loucks said:
I built a small miter box that is held in y bench vise by a T shaped tongue. I use a small flush trim saw to trim the plugs down to size. Very smooth, fast and safe!

Paul Hughes said:
Dave:
I agree with you about "WATCHING THE FINGERS" when cutting off the blunt end of plugs. I cut plugs on my band saw using a pair of pliars to firmly grip the tapered end of the plug. I also make sure the entire plug is laying flat on the band saw table when cutting it to keep it straight during the cutting process. Finally, It is a good idea to wear eye protection because the part being cut off can snap and fly back towards your face.
Paul H.

Andrew Pensavalle said:
Dave,

See my topic "using the Kreg plugs". I found out that the plugs come in one length and that length is to allow them to be use in 2 x 4 lumber. If you are using anything like the normal 3/4" lumber, you have to lop off about 3/16 to 1/4 inch off the blunt end or be prepared to use a chisel or a lot of sanding. I found the easiest way for me was to use my stationary scroll saw to do the trimming. Watch the fingers......LOL. Another down side is that you might not be able to find plugs in matching wood or wood that will stain up the same as your project wood. However if your plugs are placed well, it can add an appealing look to your project. I don't think that Kreg offers it, but there are commercially available plug cutter jigs for pocket holes if you plan to do a lot of pocket hole joinery or if you want to guarntee that your plugs are from the same wood as you are using.

I hope the added information helps.

Andy
Drill is worn out, which makes the diameter smaller. Replace the drill.

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