Thread: Wood plugs - colour

How thick will the top be?

I believe that you will not have enough material left in a single sheet ply top to support anything if you are going to recess the bolts and plug them.

I am guessing that the top would most likely need to be done as a form of torsion box, with substantial timber blocks in the core at the mounting points, absorbing the load from the skins over a wide area and coupling it to the mounting bolts and legs. I would also be very wary of a single bolt per corner arrangement unless the leg assemblies have full length stretchers very well integrated into them. With a single bolt per corner arrangement as shown in the pic, racking forces applied by people inadvertently pushing the end of the table, e.g leaning their bum against the end while standing, or pushing a chair backwards with hands at table end when leaving chair, will couple from the top to the leg assembly via the bolt or screw, trying to work the fastener in the hole and crushing material ultimately leading to structural failure and collapse.

You can buy tapered plug cutters at Carbatec & McJing's. Cut the plugs from whatever material you like and tap them in with a bit of glue on them. Then pare them down flush & sand.

Thanks, guys. I was planning to face glue 18mm ply boards to make a really solid top. Not quite sure what you mean by torsion box, Malb. I think you might a little more experienced at all this than me! Any chance you link to an image or a video? Thanks

Originally Posted by zoovegroover

Any chance you link to an image or a video?

Sir Google can help you with that request. Search for 'Torsion Box' and click on the images tab, that should give you an idea of what malb means. Although in my opinion a 36mm ply piece will be stiff enough for a small table like that (i assume that it's a coffee table ....right?). You may find that face gluing ply isn't as easy as it seems. I've done a few before and you need a lot of weight evenly distributed on top to 'clamp' the two faces together.

The plug cutters mentioned above may not be big enough for your needs if you are trying to hide bolts. In the past i have used dowels to cover similar sized holes but then you are limited in colour somewhat unless you want to have a go at making your own. Have a look on your tube if you are interested in making dowels, Mathias Wandel has a good channel showing how to make them. That way you won't need to buy more one-use tools you can just use a chisel or a plane blade.

Good Luck..

Hi,personally I think the inset plug is probably decorative and doesn't hide any fixing.
If I were making the table I would screw the leg assembly from underneath.

I wouldn't think a thick top is necessary or desirable as the design looks fine as it it.
If you want to inset a decorative disc in the top it can be drilled out and a plug made with a plug cutter,for larger discs use a forstner type bit and then turn your infill on a lathe from contrasting timber.Your infill could also be made square or rectangular making it easy to cut and fit.

Thanks for all the tips, guys. Torsion Box looks a little advanced for me! I'm hearing forstner bits shouldn't be used in a hand drill. Is that your experience, too? I don't have a drill press, and I couldn't get a slab that big under it, even if I did!

Buy a simple plunge adaptor for your electric drill, this will allow you to drill at exactly 90°. Another alternative would be to use a router fitted with a template guide, with this you could use any shape you want.

Keeping with the angular look though why not use square inserts instead of round?

I have used forstner bits in a cordless drill,they are a bit safer if used at lower speed and they are not really big diameter ones.
I prefer the carbide tipped ones myself,have only bought quite cheap Chinese ones off ebay but they work fine for me.

Originally Posted by zoovegroover

Thanks for all the tips, guys. Torsion Box looks a little advanced for me! I'm hearing forstner bits shouldn't be used in a hand drill. Is that your experience, too? I don't have a drill press, and I couldn't get a slab that big under it, even if I did!

I wasn't aware those drill guides even existed. Great tip, thanks! Router template is another good idea. I've never used a guide bushing in my router but this would be a good excuse to try it.