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I am just finishing my first project using the Kreg system of joinery exclusively. This included making up panels by joining six inch wide boards. Needless to say, I have a lot of holes to plug. I found that the plugs do not fit all the way into the holes and am going to have a lot of planing, chisleing and sanding to get the plugs level with the surrounding surface.

Is there a secret to this. I cannot make the holes any deeper. Is part of the game that you have to trim the untapered end of the plugs to fit your needs? Anyone else run across this situation? None of the videos address this problem.......I think.

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I find that using Minwax's Wood Filler works well. Scrape off any excess, let dry, and sand to a smooth finish. It stains well and is relatively inexpensive to use.
If you have a small router, try using a small hinge mortising bit, and adjust it leaving it just a bit shy of completely touching the wood surface. Take several,small passes, until only a small amount remains above the surface.Sand that little bit off,until smooth with the rest of the wood.Fill,sand& stain as requiried.
Andrew, David's suggestion regarding the router bit is a very good one. Take 90% of the plug off with that, and then sand flush. The reason your plugs are so long is because they're designed to work just as well in a 2x4 as they are in 1/2" material. The thicker your wood, the less material you're going to need to cut/sand off of the plug.

Also remember that pocket-holes can usually be hidden on the under or back side of your project where there's no need to plug the holes afterwards (depending on your style/preference).

Good luck!
Never knew why the plugs were so long. It just goes to prove,even an old timer like me can learn something new every day. Keep up the good work.Glad to see you moitering things.Don't know of any other tool manufacture that does what you're doing. Thank you for making this web site.
David,
Just so you know, we get that question a lot! Very glad I could help. Also, thank you for your compliments on the site. We're very glad that users like yourself have been able to come here, gather information, get questions answered, post their project photos to inspire other Kreg Jig owners, etc. The site has been extraordinarily well received so far, and we hope that our customers continue to find it useful!

Good luck, and good woodworking!
-KregRep

DAVID CZUPRYN said:
Never knew why the plugs were so long. It just goes to prove,even an old timer like me can learn something new every day. Keep up the good work.Glad to see you moitering things.Don't know of any other tool manufacture that does what you're doing. Thank you for making this web site.
Thanks to all for the suggestions. At least I know that it is not something that I did not do correctly.

I too would like to express my complete satisfaction with this forum. I know of no other manufacture's site that is as helpful as Kreg. Thanks again to all.

By the way, I have found that the simplest way to solve my problem is taking a few minutes....well, several minutes....and cut off abou 3/16 of the blunt end of the plugs on my Hegner scroll saw.
So, Don, you are saying to skip the plugs all together and just fill the holes?

Don Grubish said:
I find that using Minwax's Wood Filler works well. Scrape off any excess, let dry, and sand to a smooth finish. It stains well and is relatively inexpensive to use.
I sand all the plugs before glueing and inserting them thus leaving less sanding afterwards and they insert farther and easier. The key here is lightly sand.
Andrew,
This is really a good tip.


Andrew Pensavalle said:
Thanks to all for the suggestions. At least I know that it is not something that I did not do correctly.

I too would like to express my complete satisfaction with this forum. I know of no other manufacture's site that is as helpful as Kreg. Thanks again to all.

By the way, I have found that the simplest way to solve my problem is taking a few minutes....well, several minutes....and cut off abou 3/16 of the blunt end of the plugs on my Hegner scroll saw.
Thanks, Phil. I have used that system a lot lately and it really works great. I'm becomming a whiz at guessing what 3/16 looks like.....LOL
I like to use a dovetail/flush cut saw to cut then close the the surface then sand then the rest of the way. Often just a bit of wood filler of your choice may be needed.
I have a Dremel multi-max that I use with a flush cut blade. It cuts through the plug in a few seconds, then I sand it flush and fill with wood filler if necessary.

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