Pocket Hole Plugs Cutting Sled for the Kreg Jig

I was looking for an inexpensive or alternative way to complete my Kreg Jig accessories.

Kreg Jig Work Platform

So after I build my Kreg Jig Work Platform, which you can see on the link, not a step by step instructable as I believe is very easy to build (photos is all you need for the idea) and measurements are up to you and what stock you have available; I looked for alternative screws for the system, as the Kreg ones are not available in my country.

Kreg Pocket Hole Screws Alternatives

So let me explain a few things about these alternative screws before you grab my throat :)

I think the Kreg Jig system is one of the best products that Kreg came out with.
By saying that personally I have a problem, the Kreg does not exist in my country so I always have to import from overseas (via air freight) my stock in screws.
OK, I do have a small stock in the shop but since they cost me almost double the price to stock them (especially for low budget projects) I needed to find an alternative.

They way I come up with was to use the nearest to length I needed screw (maybe one or two millimeters off) that I could find in the market i.e. for coarse thread 1”1/4 I use galvanized chipboard screws 3.5X30mm together with an M4 or M5 washer.

I have no way of testing the strength between this alternative and the Kreg screws, but since the Kreg Jig system advertises that is so strong and needs no gluing, then if I use the alternative screws with glue on the joints then is a very strong joint also.

Now is about time to complete the set with a Kreg Pocket Hole Plugs Cutting Sled, which It’s more like a dowel cutting sled that allows you to make two different cuts with it, and end-up with a Pocket Hole Plug.

Step 1: Step 1 - The Base & Fence

For the sled base measures 48cmX33cm (19X13”) and the fence (4cm/1½ high).
I used 18mm (¾) marine plywood for both base and fence, joint together with glue and biscuits.
<p>At step 4, if you cut your stop block at 15 degrees it would hold the plug in place for your second cut.</p>
<p>money saving ideas are always appreciated. Good job!</p>
<p>Hi Stelios,</p><p>Thanks for that idea. I will dive into the workshop now and see if I have enough material to make one straight away. Never thought of making a jog. Nice!</p><p>As for screws, these are the screws I use. (see image) I found them in Super Home but Elinas has them as well I think. So widely available in Cyprus. The nice thing is that they are in Inches, so it is easy to use the Kreg screw length guide.</p><p>I have used them and it works well. The thread is between course and fine, so works for soft wood and hard wood, but it is a bit of a compromise. Anyway, I always use glue as well.</p><p>Yassas,</p><p>Lykle</p>
<p>Oh, and thanks for sharing your work.</p>
<p>Instead of using the rip fence, consider using the miter guide. If you do, you will always repeat the cut without set up. Just drop it in place and push it through. The only down side is, you may have to cut your sled in half and use a miter guide on each one.</p>
I have honestly never bought the Kreg screws. For softwoods i usually just use drywall screws and for hardwoods I use sheet metal screws with pan heads. I have yet to have any issues with my joints.
With a little experimenting, you could batch cut these. You would cut the dowel up into double length + kerf width segments. Then take your double length pieces and cut them down the middle at the other angle. You would have to set up an additional stop block to make the first cuts, but then you could cut a bunch at a time instead of alternating between the two cuts!.
Yea, you could do that also if you need so many plugs. But since the time needed to finish one is so small (just rotate the sled), personally I found this way easier and mostly safer to work with.<br>Thanks for visiting and commenting
Very interesting, Stelios. Although I have not a Kreg Jig, I see it is very useful. <br> <br>Regarding microwaving, the procedure is very useful when you must process any little piece of wood. IE when I must turn a spinning top, I soak the wood, then I microwave it and leave to dry overnight. That method relieves tensions and avoids deform the finished piece.
I haven't used any plugs on my Kreg projects yet since they're collapsible, but this is a great idea. The only improve I would likely make is to had a runner for the miter gauge slot. This would remove the need for the fence and you would not have to make sure the fence is set just right before sawing. The runner could be added with the fence in palce during the build to ensure proper spacing.
If you put a runner how would you make the second cut?
I thought about that a couple of hours after I posted the comment and I don't have a good answer. Maybe put it on a locking pivot? But then it's needlessly complicated. Your design works just fine.
Here is the trick how to set the fence distance always right. <br>Set the Jig at the cross cut angle - slide your blade into the allready cut groove - now bring the fence to the distance. <br>Return the jig for the first cut position and you are set to go. <br>
Awesome microwave tip! Does it work the opposite way? Can you dampen the wood/paper towel to make it expand?
If you damp the dowel it will expand, that how glue works, it damps the dowel makes it to expand and then hardens. The microwave dries out all moisture from the wooden dowel and forces it to contract. <br>Thanks for visiting and commenting
Excellent! I am adding this to my shop to do list.
Also, great tip on the alternative screws. The kreg screws are not available here either, and I use my supply only for the most expensive projects. Thank you.
There's another alternative which unfortunately I can get either, but someone of you might find, are the Phillips Round Head Wood Screws. Don't know its price if it's acceptable, but here it is.
No those are way too expensive here. I will stick to the first solution. Thanks.
Thanks artlife glad I could contribute a bit :)
Can't wait to build this for my Kreg. Thanks Steliart!
You are welcome rolltidehank and thanks for visiting and commenting
Great Instructable! The microwave tip is awesome, can't wait to try it out!
Thanks Uluz for visiting and commenting

About This Instructable


203 favorites


Bio: Design Communications Graphic & Web Designer Photography NYIP, PSA ---------------------------------- Woodworking 3D CAD designs Photography Scuba Diving (PADI Assistant Instructor) Iconography Painting Esoteric Studies
More by Steliart - Stelios LA Stavrinides: Pocket Hole Plugs Cutting Sled for the Kreg Jig Kreg Jig Work Platform Idea Sanding Block & Wing Nuts Key
Add instructable to: