Plugs / Caps don't fit

[Hillary Devere]

Hi

 

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?

Please advise

Thank you

H

 

[Derek]

I'm assuming you're talking about the length of the plugs. They're extra long so that they work in both thinner materials and stock up to 2" thick. You have to trim the plugs after you've glued them in place. The forum thread below has more helpful hints to that regard.
http://kregjig.ning.com/forum/topics/kreg-plugs-that-dont-fit

If you're having trouble with plastic plugs, odds are you aren't drilling your hole deep enough:
http://kregjig.ning.com/forum/topics/plastic-plugs

[Hillary Devere]

I had no idea I had to cut off 3/8 to 1/4 of the blunt end of the plug. I don't recall seeing that in the instructional dvd.
I'll try cutting a few down and see if that helps
Yes, I'm referring to the wooden plugs not the plastic caps.
Thanks


James Waller said:

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.

[Jens Jensen]

Hillery dont cut the plug first insert it in hole and cut flus with a trim saw or sand it down flush

[Steve Gronsky]

Hillary,

You don't have to fill "every hole". Only those that are visible are necessary to fill. I just stuck a plastic plug in a hole to see what it would do and it "snaps" into position. And I was then able to remove it too.

[Jens Jensen]

Take a sample board to lumber yard and buy a dowel rod and then go to my video and make your own plugs

[Steve Gronsky]

Phil,

I must say ..... that was quite a unique answer to Hillary's question. Do you mind if I borrow some of your content from time to time? I'm CERTAIN I can get some people's heads spinning by incorporating it into a question/answer.

Steve

[Anthony Lanting]

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?

[Hillary Devere]

I haven't tried the proposed solutions yet.
I really don't like the fact that the instructions or DVD's from Kreg mention anything about having all these extra steps to go through to fill these holes.
Very misleading and leaves me with a bad feeling about the company.


Anthony Lanting said:

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?

[Kerry Drake]

One thing to keep in mind is that your holes will be different depths depending on the size wood / screws you are using. The plugs are one-size-fits all (or one-size-doesn't-fit-any). Otherwise you would have to buy different size plugs as well as different sized screws....