foam plugs

I like to make my owm foam plugs from flip flop sandels, using sharpened brass tubes in a drill press. After reviewing other posts I thought I would pass along a tip that I found to speed up production.

I start by cutting out a rectangular blank from the sandel, usually 2-3 inches square with a depth a little over the final plug length. I the set the drill press depth to cut within 1/16" of the bottom of the foam. I then cut a series of plugs in a tight pattern over the entire surface. The plugs stay in the foam blank and I don't need to stop the press to eject them. When finished with the drilling I release the plugs by slicing a 1/16" off the bottom of the blank with a sharp knife or band saw.

Hi Kengore,

Thats something I used to do prior to
discovering Hollow Core Punches. You can
get a set from Harbor Freight for about $5
if memory serves. The unique thing about
the punches is that you can chuck them in
your drill press and drill through your foam
and the plugs are ejected from a port in the
side as subsequent plugs are drilled. You
can punch plugs until your arm wears out
without having to stop and they are ready
to affix to your lathe. Warm regards, Jim

Kengore & Jim;
I don't care how you make your foam plugs!!
I will never, I repeat' NEVER do foam Fly's!
Ah, what's the best Dremel tool to use? And how to you set one up?

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I feel more like I do now than I did when I got here!

Cactus

Hey Jack,

I ain't telling! I'm gonna wait till
ya finally break down and visit and then
I'll show ya.*G* Warm regards, Jim

Jack, the best setup, IMHO, isn't a dremel tool at all, it's a sewing machine motor w/an adaptor made from a 3/8-24 bolt. You can then screw on a drill chuck from any 3/8" electric drill, and it's off to the races. You can use it to turn rod handles, make foam bugs, turn powder horn plugs, etc.

You guys are awesome. I lay you 5-1 Diane peeks at this post, I swear I see dust in the air from my deck and she is 140 mile away http://www.flyanglersonline.com/bb/wink.gif

Philip

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Excus my spelling and gramma, I hooked Mondays and Fridays so I could Hunt or fish.