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Pocket Hole Plugs Cutting Sled for the Kreg Jig

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Pocket Hole Plugs Cutting Sled for the Kreg Jig

Right,
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.

 
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blounsb9997 months ago
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.
klee27x7 months ago
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.
Thanks for visiting and commenting
rimar20008 months ago
Very interesting, Stelios. Although I have not a Kreg Jig, I see it is very useful.

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.
rpjamess19 months ago
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.
Set the Jig at the cross cut angle - slide your blade into the allready cut groove - now bring the fence to the distance.
Return the jig for the first cut position and you are set to go.
nyx7029 months ago
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.
Thanks for visiting and commenting
artlife9 months ago
Excellent! I am adding this to my shop to do list.
artlife artlife9 months ago
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.
Slotted-Round-Head-Wood-Screws.jpg
No those are way too expensive here. I will stick to the first solution. Thanks.
Thanks artlife glad I could contribute a bit :)
rolltidehank9 months ago
Can't wait to build this for my Kreg. Thanks Steliart!
You are welcome rolltidehank and thanks for visiting and commenting
Uluz9 months ago
Great Instructable! The microwave tip is awesome, can't wait to try it out!
Thanks Uluz for visiting and commenting
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