DIY Project – Upcycling Our Kitchen Cabinet Doors – Phase 4 – Wood Plugs

Because I over bought the wood for the last phase, I just needed to buy one stick of wood.  I also bought more spray-on polyurethane and foam brushes.  I was going to try using disposable foam brushes to apply the wipe-on poly.  It would eliminate the need to clean the brush after every use.  I will see how this change will work out. 

I planned on getting the door parts ready for staining over the weekend.  I made significant progress on Saturday and I was ready to finish the sanding on Sunday.  First, I needed to rout out the inner rabbet for the panel and install the wood plugs.  However, I did not have enough plugs.  I never checked if I had enough and I did not.  Off to the store to buy more.  I bought enough for the rest of the doors. When I returned, I finished up on the plugs.

Prior to starting this phase, I spent time on the Internet looking for different methods to shorten the wood plugs before I could install them.  The wood plugs are too long, and they need to be shortened in order for the plug to be slightly flush with the frame.  By shortening the plug, it minimized the need to sand them down so they are flush with the surface.

I did not find anything that would help, except that most suggestions showed inserting the plugs as is. Then you would plane or cut the excess off.  I decided I would continue sanding down the plugs to shorten them.  In the process of my research, I found out I did not have my Kreg® jig setup properly.  I made the change prior to drilling the holes.  This change resulted in that I did not need to shorten the plugs as much as before.

Next, I took off the cabinet doors to cut them to size for the panels.  I got the panels cut to size, routed on the back, and the corners rounded off.

I was ready for sanding.  When sanding was done, the doors would be ready for staining.

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