Use the rotary table to cut plugs.  I know it can easily be done. 

https://groups.google.com/forum/#!searchin/legacy-ornamental-mills/rotary$20table$20clamp/legacy-ornamental-mills/tSUL3NaV74M/YjtaGUvCGF8J

But I really wanted to show my plug method.  I used my clamp and a long strip 
of wood to cut the plugs.  I set the stop on my x or y axis to the correct 
diameter, and when I knew the size was ready I cut a strip of wood so the face 
grain was up.  That was held in the clamp and a spiral downcut (1/4") bit was 
used to cut the plugs.  I opened the clamp and slid the stock down to make 
another plug until I finished what I needed.  

I used a standard procedure of only cutting the plugs 75%  deep and used the 
band saw to make them all fall out.  It's the same concept I showed above.  

For me the clamp was the secret but I think you can figure out a way to hold a 
strip of wood that can advance over the center.  

I hope this is making sense, if not ask questions and I will keep looking for 
the photos.  I recall I was talking about insets or inserts. 

-Tim

  ----- Original Message ----- 
  From: CURTIS GEORGE 
  To: Legacy-Ornamental-Mills 
  Sent: Sunday, May 04, 2014 5:31 PM
  Subject: Tricks needed.


  OK No silly Rabbits Jokes this time, Please. ;-)
  Im asking if any of you all have any good tricks to make wooden screw hole 
plugs, I want to make face plane plugs, I own a few different screw hole 
cutters, but I have a set of holes already made that I have to match, the mic. 
reads .400, none of my cutters will fit that size hole.


  I can turn a spindle and cut the size and shape to match the holes, but that 
will make plugs that are end grain and will not match the wood when stained.
  Dose anyone out there have any good ways to make plugs? Any and all 
suggestions are and will be welcome. 
  Thank you.
  C.A.G.

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