Craftsman Screw Plugs

Instructions

Step 1 - Cut Fixture: Cut fixture in MDF sheet with the right end of the cut overhanging the edge of your sheet. This allows you to use longer hardwood plug stock, and provides a guide for cutting off the plugs with a hand saw. We cut this directly into the Workstation Shelf here at Shaper HQ, but you can make this fixture in a plain sheet as well. Use offsets to tune the fixture slot for a tight fit with your plug stock. Cut the 1/2" plug fixture to 1/2" depth, and cut the 1/4" plug fixture to 1/4" depth. Step 2 - Load Stock: Load your stock in the fixture snug against a 1/2" spacer on the left side. Make sure the stock is secure and flush with the top surface of the fixture, and remove the spacer. Step 3 - First Cut: Load the plug rounding file, aligning the custom anchor of the plug template with the custom anchor of the fixture template. Make one cut across the end of your hardwood stock at full depth with 0.00" offset. Step 4 - Flip Stock: Remove the plug stock from the fixture. Rotate 90 degrees and reload following the instructions in Step 2. Step 5 - Second Cut: Cut the second rounded profile in the same manner as the first. You may need to adjust the offsets here, since the stock may sit a little deeper in the fixture with one cut already made. I found that a 0.02" offset worked well. Step 6 - Cut Off Plug: Load the stock backwards in the fixture, using the outside edge of the MDF as a guide for your next cut. Cut off the plug using a hand saw. Step 7 - Repeat: One of the key benefits to a fixture is quick repeatability. Loop back to Step 2 to make more plugs! Once you find your flow each plug should take no more than a minute or two.