Wood – How to put 5/8″ oak dowels into holes which are just barely the right size

furniturewooden-furniturewoodworking

I've got a handful of oak dowels (ok, a lot) and holes that are both 5/8" in diameter, the problem is that the dowels are just barely too big for the holes.

I'm trying to figure out easy ways to either sand down the dowels or expand the holes. I don't have a power sander and much in terms of tools.

I was thinking of putting the dowels into the freezer to see if they cool off just enough to get them in the holes or otherwise looking for an alternative to manually sanding down the ends of… a lot of dowels or buying a bench top belt sander.

Are there other tricks I can do to get them to fit nicely?

I can't find a good picture of exactly what I'm trying to make, but this shows the general idea (my holes are drilled all the way through, though):

enter image description here

Best Answer

Your best bet is to sand the ends of the dowels. A belt sander or disk sander however would not be the way to sand them. There would be way too big of chance of taking off too much or creating flat spots.

The best way, in my experience, is to find a way to turn the dowels and then use hand applied sandpapering technique around the dowel as it turns. The ideal tool for that would be a chuck on a wood turning lathe.

BTW (by the way) You do not want to be pounding and forcing the dowels into the holes with too much force. First off if your legs are as narrow as in the picture you would run a real risk of splitting the legs.

Since you will be having holes that go all the way through you will not have a problem with glue getting forced into the bottom of the hole and preventing the dowel from bottoming out.