Hollow Square Punches

As a furnituremaker, working in the style of Greene & Greene, I have chopped out more than a few square holes for ebony plugs. The accepted method for this has been to drill a round hole and use the chisel from a hollow chisel mortiser (hand held) to square up the holes. This has worked to some degree, but with limitations. One of those limitations being that a 3/16” hollow chisel was not available. Since I employ quite a few 3/16” square ebony plugs in my designs, this meant chopping out those holes by hand, with a lot of patience (and time).
This prompted me to design my own hollow square punch – not only because I needed a 3/16” size, but also one that is specifically designed to be hand held.
My early attempts did not meet expectations, but after a few tries, the new tool was actually outperforming expectations. Dozens of these were machined and made for me, by my friend Bob Hadley. Thanks BOB!
Once I had a working tool in hand, I submitted the idea to Lee Valley Tools. They liked it and turned it over to their R&D department. The Lee Valley folks made improvements and sent me the prototypes for testing. My friend George Knutson helped me run the punches through their paces. I then returned them along with comments and suggestions. We went through this process twice. I was greatly impressed with the Lee Valley R&D people – they really brought the tool to perfection!

Later this month Lee Valley Tools will have available for purchase the hollow square punches in six sizes -3/16” – ¼” – 5/16” – 3/8” 7/16” – ½”.
Use the product code 50K5920 to check on the punches availability.
I will follow up soon with a blog that details the use of the punches.

8 replies
  1. TheWoodWhisperer
    TheWoodWhisperer says:

    Congrats Darrell. I have been using one of your 3/16" early prototypes on EVERY G&G inspired project to date. It is absolutely indispensable for this kind of work. I will order a set the minute they are available!

  2. Marty
    Marty says:

    You mean I will no longer destroy mortising chisels to make G&G plugs? The fine folks at Jet won't be happy but I sure will! 🙂
    Thanks Mr. Peart and LV.

  3. Anonymous
    Anonymous says:

    Does anyone sell the ebony plugs already made? I just purchased the 3/8 punch and was wondering if plugs to go along with it were available..

  4. Anonymous
    Anonymous says:

    Hi Darrell,
    Steve Haas here in Houston. I am SO excited about my Rocker which you are currently working on. I thought one year would never get here but it is close! You have a great website and your furniture looks fantastic. I am trying to figure-out what to get next? Keep up the good work. And as soon as I recieve my Rocker you can raise your prices! Just kidding. Just saying hello and thank you.
    fred haas toyota country

  5. David H
    David H says:

    I bought a set of these punches from LV recently and am practicing with them before going into the real deal… They a quite nice, accurate and a pleasure to use. Thanks for getting these in the hands of amateurs like me!

  6. Stan H
    Stan H says:

    How recently? I was just looking for them and kept getting a search message saying no such thing existed, no matter where I looked. Can you give me details that are not from six years ago? Grateful for any info you can provide, thanks.


Leave a Reply

Want to join the discussion?
Feel free to contribute!

Leave a Reply

Your email address will not be published.

Solve : *
44 ⁄ 22 =