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George,
If you read those old articles that someone posted about Musso and his wooden plugs printed in the Fisherman some 20 years ago, you'll see that he sealed his plugs with some kind of Acrylic sealer. Acrylics simply do not penetrate, they stick, I'd bet that if you were to "Bandsaw Eddy" one of those darters, you'd find a shiny, hard coating on the inside of the thru-wire and hook holes. This means minimal time in the stuff and that only what sticks and dries on the surface is going to add to the weight.
Another thing you might try is epoxying the plug before you seal it, this will limit the surface area that is absorbing the sealer. I do this all the time to limit that very problem.
Let me know what you think...
-dave
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