I made my first Kreg project and built the Student Desk (per Kreg project plan) with birch plywood.
Not one of the plugs / caps fit into any of the numerous holes.
I've had this problem on sample boards too.
Actually, I've never gotten a Kreg Plug to fit into a hole.
I'm using the Kreg Pocket Hole System 4. I always remove the dust on the jig between each hole.
Someone suggested that I microwave the plugs for 30 seconds to remove the moisture but that didn't help.
What I don't like about Kreg Pocket Hole Joinery is having all these holes to fill.
What could I be doing wrong?
Hi Hillary :)
Are you trying to insert the "whole" plug?
The plugs are meant to go in so far (using glue) and then to be cut-off flushed and then sanded.
Also, the holes can be hidden so no one can see them. It's just takes a little ingenuity to work it into your project.
A thin bladed Japanese draw saw works well for these. I found a cheap one at Harbor Freight that works...but the handle is loose on it now- you get what you pay for!
Since you posted this nearly a month ago- have you come up with a solution yet?