I don't think I ever posted this, so here goes, in case it can help someone.
I finally got around to using the plug cutter I bought years ago. I'm
putting up a lot of door and window trim and don't like nails, so decided to
screw and plug everything. It's oak and hickory, so nails are pretty much
After boring into a board, breaking out plugs, and trying to cut them off
smoothly, I had a better idea.
I resawed a scrap of the same wood I was using to about 1/8" thick, then
bored it to get the plugs. They push right out of the cutter and are smooth
on their faces. I just tap them in the holes with a little glue and they
are smooth and even with the finished surface. I prefinish everything
before it's put up, so all the plug takes is a spot of varnish. If I use a
prefinished scrap to make the plugs, the final varnish is not really needed.
This process is so much better than the breaking out process shown in
pictures all over the place I don't see why I haven't heard of it. Enjoy