I am a stairbuilder, and I use thousands of trim screws every year. I countersink the screws into 3/16-in. dia. holes, then fill them with plugs made of the appropriate wood.
However, not one of the wood-shop supply outfits that I deal with has a source for 3/16-in. plugs or plug cutters. While researching the subject, it occurred to me that I could use a leather punch to make small-diameter plugs (see drawing). This tool, which looks like a cross between a spur and a pair of pliers, has a rotating wheel full of dies designed to punch holes of varying diameters. I ripped a piece of wood to 1/8 in. thick, and the punch spit out a perfect plug.
When I install the plugs, I first put a dab of Duco brand cement (available at hobby shops) in the hole. Then I wet my finger, pick up a plug with it, insert the plug and drive it home. I sand it immediately with my palm sander, and I’m ready to move on to the next hole.
Bob Johnston, Albuquerque, NM
