Thread: 20mm Plug Cutter

Draw the circles in pencil, cut them out oversize and shape them on a (preferably) disc or belt sander.

Turn short lengths on a lathe to 20mm dia, then slice up to 4mm.
Or perhaps you may be able to buy 20mm dowell (if you don't have a lathe) and cut that up into slices.

Originally Posted by artful bodger

Turn short lengths on a lathe to 20mm dia, then slice up to 4mm.
Or perhaps you may be able to buy 20mm dowell (if you don't have a lathe) and cut that up into slices.

I think her already has the timber and it's 4mm thick,. Its still possible to do it on a lathe by screwing the wood to a faceplate.

Make a template to use a copy ring on a router, the hole size will depend on your available cutters and copy rings, stick the material to a board with double sided tape so that the plug won't move when cut free and route away.

The template you can make with a hole saw or if you need a specific size a hole routing jig.

Originally Posted by Bohdan

Make a template to use a copy ring on a router, the hole size will depend on your available cutters and copy rings, stick the material to a board with double sided tape so that the plug won't move when cut free and route away.

The template you can make with a hole saw or if you need a specific size a hole routing jig.

Yep, or you can use a hole saw to cut a template in a reasonably thick piece of timber, retract the centering drill then clamp the template to your stock to cut with the same hole saw. If you have the right hole saws you should be able to get pretty close. If the stock you are using to cut the circles is thicker you can then rip the face off your stock on the table saw to release the rings.

If you have a drill press, go with a hole saw minus the centering drill bit. So long as the hole saw is tightened onto its thread, it shouldn't move, or atleast it doesn't for me.

Originally Posted by TinyTool

If you have a drill press, go with a hole saw minus the centering drill bit. So long as the hole saw is tightened onto its thread, it shouldn't move, or atleast it doesn't for me.

Came here to say this. I do the exact same thing.

Just remember, hole saw is outside diameter. Also, drill test in scrap first because the can move around a bit. I hold the timber in a vice, usually you dont need to clamp it down, but it might help with tolerances though.

Plenty of them(20mm plugs) on ebay and they are dirt cheap, https://www.ebay.com.au/itm/Wood-Ear...TOgNTQc-XiNYTA

I've used aldav's method a few time with success, provided the template and the work piece are clamped together you don't even have to lock the two pieces in a vice or clamp.

Hi Gents, and thanks for all those suggestions. I dont have a lathe. And I want to use nice timber. (not dowels etc). So maybe I might look at the hole saw idea and play around with it. So this would involve moving the drill in the hole saw right up out of the way. Interesting. And I do only want to cut through about 4mm, and get a nice clean cut also.

Thanks for all this advice

Paul

As suggested with the hole saw minus drill bit, but attach the timber to a substrate with double-face tape, to aid removal from the hole saw; a PITA otherwise.

Cheers,
Joe

What you want is a Tenon cutter

Lee Valley has imperial sizes up to 3" Carbide-Tipped Dowel, Plug & Tenon Cutters - Lee Valley Tools the more expensive power cutters are really for use with stick furniture.

Stubai tenon cutters Woodworking Tools : N° 3100 STUBAI tenon cutters come in 5 mm increments from 10 to 50 mm. I've used the 20 mm tenon cutter both for plugs and tenons. In Australia, The Woodworks carries them https://www.thewoodworks.com.au/shop...r-tenon-detail but it's probably worth teh minutes to check for an overseas source.

you can get a 20 mm Fisch tenon cutter from Dictum https://www.dictum.com/en/tools/wood...utter-oe-20-mm just remember that teh sticker price includes VAT, so you can subtract 20% before you add shipping

Axminister do a 8 piece set covering 15 to 30 mm plugs and mortices 8 Piece Matching Plug and Bit Set (15-30mm) - Plug Cutters & Plugs - Drilling - Power Tool Accessories - Accessories | Axminster Tools & Machinery you can also get individual Fisch cutters so compare the GBP minus VAT with the ex VAT price from Germany

Dieter Schmid in Berlin does a 6 piece mortice and tenon set (15, 20 and 25 mm) https://www.fine-tools.com/zapfenschneider.html