here's i jig i use for popper mouths. very secure and no need for sanding. i use round burr bit.

more pics

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Don...what diameter burr bit you using? Details please.;) Nice jig.

Cool idea! Will have to modify mine at some point.

Originally posted by BigFish
Don...what diameter burr bit you using? Details please.;) Nice jig.

Kind of depends on the size of the popper you are making doesn't it ;)

Jigman

for my 5 1/2" popper i use a 3/4" and for my 7 1/2" i use a 1" and a jig accordingly larger, should be a tight fit. i built this after a runin between my finger and bit:D jig is built at an angle matching plug face (20 degrees here) so as you can get a flush even cup.

Where do you get the bits????

Thats what I was wondering Sea-5...the biggest I can find is a 1/2 inch diameter thus the reason why I have to "roll" mine to get the size I want! I would love to know where to get those Don.;)

Nice afterhours :btu:

one question though, how do you weight your popper? any belly weight? or just a tail weight. I swam one the other day and it came in upsidedown :huh: maybe an oddball.

www.mscdirect.com has them

1" bit item 60459492
http://www1.mscdirect.com/CGI/NNSRIT?PARTPG=NNLMK32&PMPXNO=1969724

3/4 bit item 60464443
http://www1.mscdirect.com/CGI/NNSRIT?PARTPG=NNLMK32&PMPXNO=1969746

Thanks Diggin Jiggin!:D

Here's what I use. Its a router mounted sideways in a box (bottom, sides and front) with a cove bit peeking out the front port-hole.

Here's a top view.

Here's one more pic with a finished plug. I just hold the plug in both hands and just feed it in with slight pressure. The bit has a small round/square end point in the front . Your drill through will be you guide so it will no jump around. The box must be bolted to the bench or you will get hurt. Also buy a good bit or it will dull up and burn the wood.

Nice jig Rich...thanks for posting it.:D

slip- some early ones were weighted with .75 oz tailweights without belly weights, never had an issue with one, but there's a first time for everytrhing. sounds like tailweight is off center. pm me addy and you'll have a new one. i now weight with .57 oz tailweight and one .15 oz belly weight.

Thanks Don, but no problem on the new one.

Rich, that's a nice one too but shouldn't you have some kind of armrest or resting place for your hand close by the bit?

Slip,

I usually tuck my elbows tight to my sides keeping it close to by body and hold the arse end of the plug including the tag-end for xtra material to grasp on to. I eats it up rather quickly slow all you have to do is apply littler pressure and let the router do its job.

Routers are indeed scary with an exposed bit cranking away but its fairly easy and safe to use if you take caution and that goes with any machine in the shop. You can also do this in a press for starters just to get the idea of what it does.

Let me know if you need better pic's to see it from another angle.

Rich