Frequently Asked Questions

Q: How to Sharpen a Plug Cutter?

A: To restore the edge of a plug cutter, use a small diamond file or a fine-grit slip stone. Focus exclusively on the inside of the cutting flutes or the flat face of the cutting edge. Avoid filing the outer diameter, as this will change the size of the plug and cause it to fit loosely in the hole. A few light strokes are usually sufficient to maintain a razor-sharp edge for clean, burn-free cuts.

Q: How to Use a Plug Cutter?

A: For the best results, a drill press is highly recommended over a handheld drill. Secure your workpiece firmly and set the drill press to a medium speed (approx. 600-1000 RPM). Lower the cutter into the wood with steady, even pressure. Do not cut all the way through the board; stop just before the bottom to keep the plugs attached to the stock for easier removal later.

Q: What is a Plug Cutter?

A: A plug cutter is a specialized woodworking tool designed to cut circular wooden bungs or “plugs.” Unlike a standard drill bit or hole saw, it has no center pilot bit. Its primary purpose is to create plugs from the same project scrap wood to hide recessed screw heads, ensuring the grain matches perfectly and the fastener becomes nearly invisible.

Q: How to Use Wood Plug Cutter?

A: When using a wood plug cutter, always select scrap wood from the same board as your project to ensure a perfect color and grain match. Align the cutter so you are cutting with the grain rather than across it. After drilling the series of plugs, use a thin flat-head screwdriver or a wood chisel to gently “pop” the plugs out from the base of the stock.

Q: How to Make Wood Plugs without a Plug Cutter?

A: If a specialized cutter is unavailable, the most common alternative is to use a standard dowel. You can cut small sections of a dowel and glue them into the screw holes. However, note that dowels show end-grain, which absorbs stain differently and will remain visible. For a more seamless look, some woodworkers manually whittle a piece of scrap wood, though this lacks the precision and speed of a dedicated plug cutter.

Q: How to Cut Wood Plugs?

A: The process involves two steps: drilling and extraction. First, use the plug cutter to bore into your timber to the desired depth. Once the circular paths are cut, the plugs remain attached at the bottom. To finish the cut, simply slide a chisel or a flat-bladed tool into the kerf and apply a slight prying motion; the plugs will snap off cleanly at the base, ready for gluing and sanding.