Drilling large plugs on a small drillpress
 

I came up with a simple to build jig for my 10 "drill press that allows me to start the through holes on each end of the plug on plugs up to 12" long.

Here goes, first I swivel the table out of the way....

I took 2 lengths of two by fours and bolted them together. I then drilled 2 holes for bolts to attach it to the base of my drill and a large one inch diameter hole that is centered under the bit.
(there's a few pictures coming :) )

I then take a 1 inch dowel and insert it into the hole, this is the base for the platform that will hold the plug. I then take a small piece of wood that has a 1 inch hole cut half way thru it and place this on top of the dowel. On the other side of this block there is a dowel center that is centered directly under the bit.

This is what it looks like with the block with the dowel center on top.

Put the hole in the tail of the plug (from the lathe) on top of the dowel center and drill down thru the top.

Then flip the plug around, putting the hole you just drilled on the dowel center, and drill down thru the tail. This works well even for off center plugs but you MUST drill the head first.

The really nice thing about this jig, is that all you need to do to make it work for longer or shorter plugs, is cut a different 1" dowel that is the right length to get the base up/or down to where you need it.

Once you have the holes in both ends drilled, it's relatively easy to finish it with along bit in a hand drill... :happy:

I can attest to it's usefullness. Went over Dave's house last night and did alot of drilling!:D

Thanks again Dave.

What keeps the plug from spinning when the bit digs in? Also how are you sure that the plug is centered on the dowel?
Not questioning mind you, I feel as if my brain isn't connecting with this?

Thanks
Tony

How do you make sure the hole is drilled at the right angle and orientation?

Tony,
There is a dowel center whihc is basically like a pin on the square block I am sitting on the dowel. This pin fits into the hole created by the lathe, which is dead center...

You set the hole in the tail on the center, hold the plug with your left hand so that the bit enters where the hole is in the lip, and crank the handle with your right hand.

Striperman,
Cut the lip slot, put the lip in the plug and mark where the hole needs to go. Take the lip out, put the tail on the dowel center and hold the plug so the bit enters the spot you marked for the lip.

You are basically holding the plug offcenter in your hand, the drill wants to drill a straight line, which it will do from the offcenter starting point to the other end of the plug which is centered...

Okay, I believe the thru hole has little to do with the action, but if I don't align the hole paralell to the lip I end up with difficulty meeting the front end hole with the tail end hole. I drill 1/8 thru holes.

AHAAAAAA, Thanks Diggin

the placement of the front loop-hole determines if your plug will swim on top or dive.

I use the same basic set up diggin jiggin and it works. You have to see it work, to see how simple it really is. I hold the wood in my hand from turning. there is not enough force in a 1/8 drill to cause a problem. good pictures!!!