Official Luthiers Forum!

Anyone have a source for a 1/16", 5/64" or 2mm plug cutter? The smallest I have is 3/32".
TIA, Ken.

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Ken Franklin
clumsy yet persistent
https://www.kenfranklinukulele.com

I've made plugs that size before by cutting a toothed pattern on the end of a piece of brass tubing with the appropriate Inside diameter. They're not ideal and don't last very long but they will get the job done.

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Steve Smith
"Music is what feelings sound like"

Pocket Knife

While probably not of much use for bulk fabrication of inlays, we superglue side marker or inlay dot material to the shank end of a drill bit or 5" length of music wire of correct diameter, spin it lightly against the disc sander to flush it against the holder (thus, making a dot of correct size and diameter), then use the bit or wire as a handle while gluing the inlay in place to establish correct orientation and depth. A light tap on the holder with a small machinist's hammer to sheer the glue line releases the already mounted inlay. For delicate inlay materials, a sharp razor blade can be used to cut the dot free.

I recently used this technique to replace the red plastic side marker dots on a rebound Country Gentleman...quick and fairly painless, and much quicker than having our usual bulk supplier of dot and markers make them up.

One caution: the holder can get a bit tapered if one applies too much pressure, and can require that the holder (bit or wire) be ground back square every now and again. Last time Woodcraft had their sale on cheap, Asian-sourced metric and English brad point bits, we bought one of each kit specifically for this task - cheaper and quicker than trying to source music wire in odd sizes.

We also use this method for making up small bungs to repair drilled-out broken screws, bridge or tailpiece moves, etc., due to the lack of smaller bung (plug) cutters and those in metric sizes.

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A constellation only takes shape when one maps the whole.
- Beth Brower

I make one off, odd sized plugs with the drill/ disc sander method.

Remember,if you use a metal holder as suggested above, DO NOT use a dust collector or let the sparks land on a pile of sawdust inside the machine. Talk about a potential butterfly effect.

Thanks guys. Those are things I usually do but was looking for a more consistent long term solution in this age of inlay regulations. I've been making wooden dots as I don't care for plastic ones.

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Ken Franklin
clumsy yet persistent
https://www.kenfranklinukulele.com

I have used a pencil sharpener to create a tapered custom size plug.

http://www.veritastools.ca/Products/Page.aspx?p=152

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My memory is so good, sometimes I remember things that never happened.

Ken, have you tried using a 5/64 (or #4) countersink bit for small plugs? You can get them just about anywhere. The important thing is you need one with at least 3 flutes (4 is better) if it is to last for any amount of time. Just chuck a 5/64" bit into it backwards leaving enough cutting room for your plug stock, then chuck into your drill press and you have a micro plug cutter.

Amazon has one here https://www.amazon.com/WL-Fuller-64-CSINK/dp/B001B219NS/ref=sr_1_1/182-9119353-6211504?ie=UTF8&qid=1466992784&sr=8-1&keywords=1%2F4+X+5%2F64+C%27Sink

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Bill Hodge


One does not simply, own enough guitars!

Thanks Bill! Just what I was looking for.

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Ken Franklin
clumsy yet persistent
https://www.kenfranklinukulele.com

That's a fantastic tip Bill!

I have a method for sharpening standard 4 flute plug cutters that I think could be used to improve the geometry of countersinks for plug cutting.

Amazing what solutions are right under you nose sometimes. Thanks!