Because Club member Burrell “Buzz” Cayton of Winnabow, North Carolina, likes to make his own plugs for woodworking projects, he wanted a quick way to consistently cut plug stock to length. So Buzz created a jig that lets him cut plugs to exact length before insertion. He used two 5-in. lengths of scrap 1x2 material and two 1-1/2-in. hinges to make the jig body. Then he tightly clamped the two halves together and drilled a centered 3/8-in.-dia. hole (use whatever diameter and depth fits your needs) to hold the plug material. Buzz can now quickly cut plugs on his band saw and never has to worry about making them too short.
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