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I've had pretty good results cutting the 5 or 6 popper faces that I've done using carving gouges. I have 3 or 4 of them (different sizes) and find that I can cut just about any diameter and depth that I want with them. I hold the plug in my hand and a cutting stroke is a combination of tool movement and hand rotation. When I get to where I want the mouth to be, I sort of force my thumb into a small square of sand paper, press in and rotate left to right to smooth out the tool marks and any end grain burrs. Not always 100% successful, but paint helps fill in any hollows. On average, each one takes about 10 minutes, no noise, no heat, no power tools, etc., but I do wear a mesh type carvers glove and I always try to keep the gouge edges sharp.
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