How I Make Ebony Green And Green Screw Cover Plugs, Or Epic Fail.
I’m making some Arts and Crafts style TP holders and a towel bar that require 12 Green And Green screw plug covers. The 3/8” + ebony blanks are cut at the band saw and sanded to about 1/32” over 3/8” on the belt sander. They will not fit into a 1/2” chuck. I made a holder out of Cumaru on the band saw that fits into my 1/2” drill chuck and holds the blanks with a set screw. Slightly sanding down the corners at a 30* angle to make it easier to sand the plugs with the drill and jig. This step will eliminate a lot of the sanding. Using several layers of HF non-slip padding under the sand paper to help round over the plugs. Starting with 100 grit working up to 100...
