homemade plug cutter

I wanted a plug cutter to cut wooden plugs for fret markers for a guitar I am working on. I with an old bolt.


chopped up a 1/2″ stainless bolt


turned the threads down to 3/8″ shank so it would fit in a collet


made the other side shiny, bored the plug hole and tapered the cutting end


clamped it sideways in the mill to cut the side chip clearance

To form the ‘flute’ of the cutter where the chips clear out, I made an angled clamp block. I just eyeballed the angle I wanted and drilled a hole in a block of aluminum. Then I band sawed through the hole so it would allow clamping. The position of the end mill was also eyeballed. Position seems pretty forgiving.


fixture for holding the plug cutter at the right angle for cutting the ‘flute’


on-end view of the flute being cut

Below is the confirmation that it works! I drilled a whole bunch of plugs close together. Then I used a piece of tape to hold them all together while I band sawed them off.


future fret markers!


2 thoughts on “homemade plug cutter

  1. Pingback: Homemade Plug Cutter Made from Old Threaded Bolt | #MakerTools « Adafruit Industries – Makers, hackers, artists, designers and engineers!

  2. Pingback: making a guitar fretboard | Amy Qian

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s