Thanks to all who voted for me for the Sugar Contest! :)
Step 1: Tools & Materials
2 pieces of wood approximately 1" x .75" x 3"
Drill and drill bits
Sugar cube sample (optional)
Step 2: Make Markings
Place and center sugar cube on one of the blocks of wood and trace around it as shown.
Step 3: Drill Hole in Block
Place block of wood in vise and mark center of square as shown. Next, drill a small guide hole as straight as possible all the way through. Using a bigger drill bit (no larger than the square), drill half way through, flip block and using the sugar cube, trace the other side of the block, (as centered as possible) and finish hole.
Step 4: File Hole Into Square Shape
Place block in vise at an angle and file down until the hole becomes square and sugar cube slides through freely as shown.
Step 5: Shaping Plunger
Place sugar cube on end of second block and trace around it as shown. Continue lines on the sides for use as guidelines. Using a bench grinder, grind down block as shown until it fits freely through the first block. (see photos)
Step 6: Sanding
Using the bench grinder and/or sandpaper, smooth and shape blocks as desired. If you have any wood oil, it's a good idea to apply some all around for a nice protected finish.
I didn't have any but used petroleum jelly (vaseline), which seems to work nicely.
Step 7: Making Sugar Cubes
I thought that it would also work with regular sugar by adding a few teaspoons of water and mixing... but, I just tried it and it doesn't work. :(
Also, be sure that the brand of brown sugar you use has enough molasses it in it to hold the shape. I tried one brand from Costco that was too dry and didn't work.
After use, clean with slightly damp cloth trying to not get it too wet so as not to have it absorb moisture which may cause warping and expand, thus causing the plunger to stick. Apply oil or petroleum jelly if needed for continued protection.