Wooden Plugs not fitting properly

[Bonnie J Mello]

Just recently purchased the R3.  Worked great on our project - building a farm table from 2x12 pine boards we have had in our garage forever and sections of our old front porch columns we for the legs.  Everything went together just fine - but when I started to put the wooden plugs in - I could not even get some of them started in pocket holes.

Any suggestions - what did we do wrong - how to correct?  Right now I am thinking of using my dremel tool to make them a little bigger.

Also we had a problem with the long screw driver not staying in the screw head.  It kept slipping out of the slot on top of the screw (used Kreg screws)- used a variable speed drill.

Any & all suggestion will be appreciated.

Thanks,

bjm

[Tim Grace]

Ensure the bit is square to the screw. I've found that the longer one works a bit better, but still have them slip out from time to time.  I've also picked up a couple of #2 square drive bits with hardened tips, they are less likely to round off as a result of slippage.

I've had difficulties with plugs, as well.  I've had to use a screw clamp to force them into the holes and still had gaps around them - especially with the pine/paint grade plugs.  The oak plugs into oak seem to work a bit better. The plugs and wood will swell with temperature and humidity.  Try sanding the plugs a little rather than than enlarging the hole.

[Bonnie J Mello]

Tim,

Thanks for the info.  I finally figured out one trick to get them to go in - place and then tap downward with a hammer.    I will definitely look into the #2 bits with hardened tips.  The first night I tried working with them - the humidity was pretty high,  I think that may have caused the pine plugs to swell just a bit.  When I worked on them last night - the humidity was much lower and seemed to go in easier. 

Bonnie J Mello

Fresno, Texas

[KregCS]

Bonnie, 

It sounds as if moisture is your issue with the plugs. Due to the different climates that they travel through from our warehouse, they can expand and contract, making them pretty snug in some holes. A little trick that we have learned is to take a few of them and pop them in the microwave for a few seconds. This evaporates the moisture and should make them slide into your holes a lot easier.  

As far as the driver goes, you will want to make sure that your drill and driver are following the same angle as the pocket hole. If they are not, it will cause the driver to bind and can increase your chances of it slipping out. As long as you follow that and have your driver fully engaged, you should have much better success while driving your screws.  

[Tim Grace]

Never thought of popping them in the microwave.  Thanks for the tip!

KregCS said:

Bonnie, 

It sounds as if moisture is your issue with the plugs. Due to the different climates that they travel through from our warehouse, they can expand and contract, making them pretty snug in some holes. A little trick that we have learned is to take a few of them and pop them in the microwave for a few seconds. This evaporates the moisture and should make them slide into your holes a lot easier.  

As far as the driver goes, you will want to make sure that your drill and driver are following the same angle as the pocket hole. If they are not, it will cause the driver to bind and can increase your chances of it slipping out. As long as you follow that and have your driver fully engaged, you should have much better success while driving your screws.  

[Ken Darga]

re Moisture content

What's the percentage of moisture in the material?

This can be measured with an appropriate suitable moisture meter.

What's the expansion rate---time and temp???

Calculate it out and determine what the size has expanded to, after it has increased from approx 15% moisture to "X"....%

I think you'll find that it increased very little in dia.

The drying process needs to be SLOW---putting in a microwave oven and zaping it on a HIGH setting/overheating the material, may cause the objects to fracture.

If the temp is too high, and for only a few seconds, only the moisture near the surface will evaporate---

the center will still contain more moisture.

This is what I do---

if a plug fits to snug, I just sand it down a very small amount at a time, make a dry fit, remove it, apply some glue and press it in place.  

Allow the glue to dry and finish it flush.

You can also set it out in the sun on a warm day,

place the pegs on a black pan or tray---

allow them to dry out naturally.

I purchase pegs by the hundreds, and store them in an airtight (ziplock type) plastic bag, them store the bagged pegs in a plastic jar with a screw-on lid, 

and don't have any problems.