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Old 12-08-2010, 06:27 PM   #2
numbskull
Oblivious // Grunt, Grunt Master
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Join Date: Nov 2005
Location: over the hill
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Obviously, you first turn your body and thru drill on center.
The next step is to cut the face. To do this I use a drill press and a salty ball (rotary rasp). As you cut the face it will generate a lot of downward pressure on the plug and rotary force as well. Holding it in your hand is ill-advised, so I made a jig. Just a board with a vertical V block screwed to it. At the base there is a 1/8" pin that I can set the tail hole on. Take a compass and draw a circle centered on this pin that is the same radius as your plug's at the max diameter ( which is 2x the radius for Back Beach's benefit), then position the walls of your V block against this circle and fasten it down.

Higher up drill a center hole through you V block to put a screw in. This screw will keep the plug from rotating when the rasp bites it. You can't hold it by hand alone.
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