Drill Chucks

[reible]

That is one massive plug cutter!

Unless you have a speed reducer or powerpro head stock you are going to have a speed problem as well as a mounting problem. A big bit like that will be in the 250 to say 500 rpm range. Much slower then is possible with modern day shopsmith machines.

The lower speed would be for hardwoods, higher for softwoods.

Since you want to cut a plug this would be another option, but again costs more:

http://www.woodcraft.com/Product/154936 ... uller.aspx

Other options if you have the equipment would be to use a router. Or simply use the lathe to do them.

The cheapest way might be to see if you can find a matching wood dowel or plug that you can simply buy. Dowels normal have the wrong grain direction, so best to look for plugs with face grain.

Other options might be a hole saw for the larger plug then a smaller plug cutter to fix the hole that is left from the hole saw.

Anyway these are a few of the ideas I came up with at the moment.

Ed

[gr8mesquite]

I've been slicing plugs from purchased hardwood dowels (Purpleheart, Yellowheart,Padauk,Canarywood,et al, 3/4" - 1 1/2".) There are 2 issues: as you pointed out, the cut produces end grain--I would prefer face grain; these larger sized exotic hardwood dowels are rather expensive and I'm going thru them quickly. I was looking for an easy fix for both issues.
BTW, I have been boring 1 1/2 Forstner bit holes for the plugs using the SS at its lowest speed. I've had no problems whatsoever, with clean, perfectly formed holes, no burning, stalling, etc --just a clean smooth operation. However, if need be, I do have a speed reducer.

There are other 1"+ plug/tenon cutters around with smaller shanks--I just happen to be drawn to these CMT ones. In the absense of a 5/8" chuck, I might try a 5/8' to 5/8" shaft coupler, which is an inexpensive fix.

Jerome

[JPG]

I realize that this is a resourceful group--that's why I posed the question here.

So, I want to buy a 1 1/2" plug cutter ( http://www.amazon.com/gp/product/B0017Q ... 0LWTFI0BL8 ) which has a 5/8" shank.

Right now the only option I'm seeing is to flatten the shank and get a
5/"8-to-5/8" set screw coupler.

I would welcome any other ideas.

Thanks

Jerome

IIWM, I would not hesitate to grind a small flat on the shaft. Just big enough and positioned to align with the coupler set screw.

[beeg]

Reduce the shank to 1/2".

[gr8mesquite]

Other than buying a metal lathe, how do i reduce the shaft size?

[dusty]

Unless you have a whole bunch of plugs to cut, I'd suggest that you cut them using the bandsaw and clean them up using the belt sander. I came to that conclusion real fast when I saw the price for a 1 1/2" plug cutter.

[kenbu]

There is a machinist on the penturners forum that does this kind of work well and inexpensively. I have been pleased in my two dealings with him. You could send him the cutter and have him turn down the shaft to 1/2 inch. If that interests you, PM me with your email address and I'll forward it to him so he can get in touch.

Ken

[hgk]

Here's a 1/2" shank cutter for $30.
http://www.ebay.com/itm/1-1-2-Plug-Cutt ... 27f5e61284