Thursday, August 4, 2016

Plugging unwanted holes

Since I decided to restyle the drumkit, I took the option of plugging unwanted openings: damper attachment, tom and bassdrum bracket.

The idea is to give it a cleaner look. I usually place my rack tom on a snare stand, so bracket was redundant.

In order to plug the holes properly, I followed a few steps:

1. Filling the existing holes with pieces of wood, whether it's plugs (cut with a plug cutter) or wood patches, carved to shape. I sometimes had to enlarge the existing holes to fit a standard plug, like I did with the damper mounts. It's OK if it's not very clean, it's only the first step of the process.

2. Hollowing out a shallow cut (using a forstner bit for holes or a router for shapes) that overlaps the filling plug, both sides of the shell. Then glue thin patches trying to match woodgrain. This has 2 advantages: give a cleaner joint (thanks to superficial routing) and a stronger bond (finishing plugs kind of seal the filling plug into the shell).
 
A very convenient one handed Makita wood trimmer, perfect for that kind of light woodworking. The copying ring follows the edge of the jig, that's 2 mm wider than the cut. I used hot melt glue on masking tape to fix the jig to the shell.
In this case I used a piece of thick gloss cardboard from a shoebox to cut the routing jig. Worked fine.
There you have it. A nice pill-shaped cut, ready to have finishing patches glued.

3. Sanding or routing off the finishing plugs flush with the shell.
Here a few 15mm finishing plugs, actually one long plug cut into slices
If you pick the right wood tone, plugging can become barely noticeable