A plug cutter is a handy tool that every woodworker should have in their arsenal. This guide will show you how to make your own plug cutter so that you can cut perfect plugs every time.
First, gather the following materials: a block of wood, a drill bit slightly smaller than the outside diameter of your desired plug, and a dowel rod or other cylindrical object that is slightly larger than the inside diameter of your desired plug. For this example, we will be making a ¼” plug cutter.
Next, mark out the length of yourplug on the block of wood. For our ¼” example, we will need a 1” longplug . Once you have marked out the length, use the drill bit to drilledown into the center of your mark. Keep drilling until the bit comes outthe other side of the block. Now take your dowel rod or other cylindricalobject and insert it into the hole you just drilled. This will serve asa guide for cutting your Plug .
Now it's time to start cutting! Using a sharp chisel, start at one endof your hole and begin chopping away at the wood. Be sure to keepyour cuts perpendicular to the surface of the block; otherwise youwill end up with an angled or lopsided plug . Once you have cut allthe way through, remove yourPlug from theblock and trim off any rough edges with a knife or sandpaper. Andthat's it - you've now made yourself a brand new Plug Cutter !