TESTED: Star-M countersink and plug-cutter set
Review and photos: Damion Fauser
Reinforcing project construction with screws and then disguising the screw heads with timber plugs has long been utilised in workshops the world over. Most often woodworkers are required to drill out this arrangement in several stages – pilot hole, shank clearance hole and then the countersink or counterbore to accommodate the screw head, this final step requiring to be done in a size that matches a subsequent plug cutter, often from a different tooling manufacturer.
This two-part-set from Japanese maker Star-M greatly simplifies this multi-stage drilling to one operation and provides a matching plug cutter.
The drilling is achieved with a combination set that combines a tapered single-fluted central drill bit to cut both the pilot hole and the shank clearance hole in one. This is mounted inside a second tool which is a single- fluted countersinking cutter. The protrusion of the tapered drill can be easily adjusted by loosening and tightening the inset grub screw with the provided allen key. Star-M recommends a maximum protrusion of 20mm.
I tested this cutter set in a piece of Victorian ash at 2000rpm and it cut cut fast and relatively clean, with a little lifting/chipping at the perimeter of the countersink hole on the surface, but I would as likely put this down to the brittle nature of the species.
The matching plug cutter also cut fast and clean in the Victorian ash and the resulting plugs measured out perfectly cylindrically along 12mm of plug length and approximately 0.1mm less in diameter than the countersink holes into which they would be inserted. This resulted in an easy insertion and a very slight visible gap when dry-fitted. Choice of glue would influence how visible or not this would be in the completed glued and cleaned assembly.
Both tools have a standard 6.35mm (1/4") shank and therefore can be used in any handheld or pedestal drilling tool.
Two set sizes are available from Japanese Tools Australia, with the 3mm centre drill and 9mm plug set costing $39 and the 4mm centre drill and 10.5mm plug set costing $44. For the increased efficiency that this arrangement affords, as well as the quite good quality of the finished result, I consider this to be exceptional value.
Review tools provided by and available from Japanese Tools Australia, www.japanesetools.com.au
Damion Fauser @damionfauser is a furniture designer maker and woodwork teacher in Brisbane and a regular contributor to Australian Wood Review. Learn more at http://damionfauser.com/