This may be obvious to all you builders, but it wasn't to me. If I save someone the aggravation I had, this post is not a waste.
I had about 200 holes to plug after my planking, so I bought a tapered plug cutter at Rockler and proceeded to use all my scrap 3/8" planking material to make the 200 plugs. This is the cutter I bought.
Plug cutter.jpg [ 24.72 KiB | Viewed 630 times ]
The problem I had is that the 3/8" material did not provide enough depth of wood to get the taper down to under my hole size of 3/8". The smaller part of the plug is higher up in the cutter, so you should use material over 1/2" thick to make your plugs. Since I used 3/8" material, all the plugs I had were a little too large to fit the holes. Like a dummy, I sanded a little chamfer on the plugs to get them in.
I should have bit the bullet and just made new bungs. You should also test your countersink holes and plugs before you make 200 of them.
Another live and learn moment.
Completed Malahini (launched 6/24/2012)http://bobsboatbuild.blogspot.com/