PRO PLUG SYSTEM
APPLICATIONS
DECKING
The Smart-Bit Pro Plug System will give a great result in the installation of wood decking. This result is functionally superior to hidden clip-systems. On occasions when clip systems are used, face screwing starter and end boards is still required. The Pro Plug System is the perfect answer in these situations.
FLOORING
ILarge plank flooring often requires face screwing or nailing. Additionally, even when using traditional dimension tongue and groove flooring, face screwing may be needed for corners and stairs. The Smart-Bit Pro Plug System will add a high degree of finish and craftsmanship to these applications.
GENERAL WOODWORKING
Any general woodworking task where plugs have been needed or considered is now the perfect place to consider the Smart-Bit Pro Plug System. Furthermore, it makes plugging so easy that we expect many woodworkers will find new uses, including the purely decorative effect of using a different species of plug than the primary work piece.
USAGE NOTES
WHAT YOU WILL NEED
Pro Plug Tool for Wood. Depending on the number of holes and density of the wood you are drilling, extra replacement bits may be necessary.
Pro Plug Plug & Fastener Kit. Kits vary by wood plug species and fastener, and contain an equal number of plugs and fasteners. For decks, a general rule of thumb is 350 pieces for each 100 square feet (9 square meters) of decking. There are two available types of fasteners: 2-1/2" (62mm) stainless steel screws for decks and other outdoor projects, and 1-5/8" (42mm) hardened steel zinc plated screws for flooring and other indoor projects. Each kit also containers driver bit(s) and a Pro Plug Glue Nozzle.
Your decking or flooring manufacturer's instructions.
A power drill.
A power sander with sandpaper. 60 grit works well for dense boards such as Ipe. For less dense boards such as Cambara or Meranti, 100 to 120 grit is suggested. Please consult your decking or flooring installation instructions for their sanding recommendations.
A source of compressed air (from a small can or a compressor).
A water clean-up wood glue. with a cap that is interchangeable with the Pro Plug Glue Nozzle. Wood glue products made by Elmer's® that work with the nozzle are available in the following sizes: 4 oz. (118ml), 8 oz. (236ml) and 16 oz. (472ml). Wood glue products made by Franklin International (sold under their Titebond® line) are available in the following sizes: 4 oz. (118ml) and 8 oz. (236ml). For exterior projects, be sure to use appropriately rated exterior glues, such as Elmer's® Waterproof Wood Glue or Titebond® III. (Note: Epoxy adhesives can also be used for plugging, but will not work with the Pro Plug Glue Nozzle.)
A plastic or wood mallet.
A rag.
HOW TO USE THE SYSTEM
Read your decking or flooring manufacturer's installation instructions.
Determine the locations where screws are needed.
Pre-drill holes with the Pro Plug Tool for Wood. The hole is complete when the stop collar stops spinning.
Blow out sawdust from the holes with compressed air.
Insert Pro Plug Fasteners so they are flush with the countersink at the bottom of each hole. (Note: Wood should be kept dry and holes free of debris before gluing and inserting plugs.)
Attach the Pro Plug Glue Nozzle* to the wood glue bottle. Follow the glue manufacturer's usage recommendations, including working temperature and set time.
With the work surface in a horizontal position, place the nozzle in the hole and push the glue bottle down. This will open the nozzle. Gently Squeeze.* Turn the bottle a 1/4 turn to ensure full coverage of the side wall. Pull the nozzle out of the hole. This will close the holes in the nozzle. The objective is to coat the inside walls of the hole while leaving as little glue at the bottom of the hole as possible. You can glue several holes at a time and then go back to insert the plugs, so long as you do so before the glue begins to set. Excess glue may occasionally build up on the nozzle tip. Use a rag to wipe it off.
Insert a Pro Plug Plug in each hole, chamfered end first, with the wood grain aligned with the work piece. (Note: All plugs are face grained.) Using only moderate force, pound plugs in with a plastic or wooden mallet until flush or nearly flush with the work surface. Any excess glue can be wiped clean with a damp rag.
Sand the work surface. We recommend delaying sanding until after the glue has set following the glue manufacturer's directions.
Download: Pro Plug System for Wood Installation Instructions (pdf)
