The time has come to build a wood plug.
I will create a simple 3D drawing of the plug and cut it from a solid block of wood. (a 6X6 cut 16" long)
Here is a look at how I do it....
First I draw a side view of the body I want to make and then I draw a view of the rear. I then put those in my CAD program.
Then I create a solid shape using the two views. I also add a bottom to the drawing which helps make using the plug very easy. (more on this later)
I cut the 6X6 to 16" long.
Then I attach the 6X6 to the cnc machine for cutting. You could also draw your profile on the side and back of the block and carve it by hand if you do not have a cnc machine that will do the job.
As you will see, I had no issue cutting the 6X6 block to shape on my machine.
Here I start the machine and it does a lot of the work for me.
I can use a ball end mill for a smoother finish. But, for this plug I will sand it to the final shape by hand so I just want it roughed out.
The plug is looking just like I drew it.
Here is a look at the tool path for the finish pass.
And here is a look at the results.
My custom wood plug is looking pretty good so far.
I will flip the plug and remove about half of the remaining wood below the plug. The wood I leave is called a "buck". It is shaped and used to help make forming a body much easier.
I am going to make the plug and the buck as one unit. You could make each and glue them together. That is really the easiest way. But, I like a challenge. So here goes.
Before I start sanding I will cut off the extra material on the ends.
I want to note that you do not need a vacuum forming machine to pull a good body. IMO all you need is the right material, a good plug, a even heat source to heat the plastic
and you can use a flat surface with only one hole in it to form a good body. And "yes" almost any shop vac will do the job if you use only one hole. Making a good plug and using a
buck is the secret. In case you are wondering "The size of the hole should be the same size your shop vac hose fits into".