Hello all,
Before FCS Fusion plugs were available here in Australia We had problems installing FCS plugs in EPS Blanks.
They were weak when installed directly into the blanks and the EPS hated the constant heat generated by the epoxy resin, causing it to melt and bubble up everywhere.
I’d like to share this method I came up with before Fusion plugs were around to combat the problem.
I use Fusion for production boards at the factory, however I still use this method when making my personal boards in my shed at home. It’s just so quick and easy.
You can add different high strength inserts such as core cell that will hold screws etc.
No extra mixing of epoxy to secure is required which I really like.
I’m not re inventing the wheel or anything but here it is;
Photo 1.
You buy two whole saws, one bigger then the other (next size up).
Cover the small one with sand paper (120 some disc cement and some tape down below. This is to drill out the holes in your EPS blank.
Make a jig to line up your fin marks on the blank, and then use it as a guide for your holes. As you can see there are lines for centre and rail on the jig so you can get it dead centre.
Photo 2 and 3.
Cut holes in your blank.
Photo 4.
Change from the small to the large hole saw.
Use the bigger jig guide and drill into the flat (bottom) side of some PU off cut, or what ever you what.
NOTE: You don’t want to drill right through the PU so choose a bit thicker part. Why?
1, it’ll get stuck in the whole saw.
2, it will make for and easier job next step
Photo 5.
Get your planer and rip into the top of the PU until the tops of the holes are showing. This keeps them all uniform and flat on top.
Photo 6.
Pop em out.
Quickly run the daggy bits around a course sanding block keeping the bottom flat with the sides and not loosing the shape of the plug.
Photo 7.
Your plugs will fit nice and snug.
If Not, add thicker sand paper to the small hole saw-NEXT TIME- to make a slightly bigger hole in the blank. Or sand around the PU plugs slightly.
The back 6 wholes I get away with only one plug per hole, where as the ones up front will require two. This creates no problems, sink them in half/half and make sure they meet flush (you can add quite a bit of pressure to force them together (or glue em if you must, I never have)
Sand them down with your power sander then use whatever grade sand paper you think necessary to make flush.
NOTE: Insert the plugs before the shaped blank is fine sanded.
Hope this helps some of you guys/girls.
Yorky