## Introduction to the Pro Plug System

The Pro Plug System is a face-fastening method designed to secure dense Brazilian hardwoods such as Ipe, Cumaru, Tigerwood, Garapa, and Massaranduba using stainless screws and matching hardwood plugs. This system creates a concealed fastening method where screws are driven through the face of the board but covered with species-matched wooden plugs, resulting in a smooth, uninterrupted, screw-free surface.

The Pro Plug System consists of:

• Stainless steel screws

• Hardwood species-matched plug packs

• The Pro Plug drill tool with integrated depth stop

• Glue nozzle or applicator

• Driver bits

• Predrill and counterbore system built into the tool

The system is designed to ensure consistent plug depth, prevent mushrooming, and maintain a clean, uniform finish across hardwood decking surfaces.

## When to Use the Pro Plug System

Pro Plugs are used in areas where hidden fasteners (clips or edge screws) cannot be installed. Typical applications include:

• Starter boards near the house

• End boards where a groove cannot be cut

• Picture framing and decorative borders

• Breaker boards

• Stair treads and risers

• Fascia boards and skirt boards

• Rail caps

• Tight spaces or transitions where clips cannot reach

For interior rows of grooved boards, hidden fasteners are preferred. For all exposed surfaces, the Pro Plug System provides a concealed fastening alternative.

## Components of the Pro Plug System

Pro Plug Tool

The Pro Plug drill tool performs two actions in one step:

1. Cuts a shallow counterbore into the top surface

2. Drills a pilot hole for the screw at the correct depth

The tool includes:

• A hardened steel cutting ring

• A rubber depth-stop collar

• An integrated pilot bit

• A hex-shank for drill/driver compatibility

The depth stop ensures consistent screw placement and prevents over-drilling.

Screws

Pro Plug screws are typically:

• 2½” long

• Stainless steel (305 or 316 grade depending on environment)

• Trim-head

• Designed for dense hardwood penetration

• Used with the driver bit included in the kit

Plugs

Hardwood plugs are made from the same species as the deck boards and are:

• Pre-cut

• Tapered to fit the counterbore

• End-grain exposed to match the deck surface

• Installed with glue beneath the plug

## Step-by-Step Pro Plug Installation Instructions

### Step 1 — Predrill and Counterbore Using the Pro Plug Tool

• Position the tool on the board surface.

• Drill until the rubber depth stop contacts the wood.

• The tool will create both the counterbore and pilot hole in one action.

• Remove dust from the hole before installing the screw.

The counterbore must be clean and consistent to ensure the plug sits correctly.

### Step 2 — Drive the Stainless Steel Screw

• Insert the supplied stainless screw into the predrilled hole.

• Use the provided driver bit.

• Drive until the screw head seats at the bottom of the counterbore.

• Avoid overtightening to prevent stripping or sinking too deep.

Proper depth ensures the plug sits flush with the deck surface.

### Step 3 — Apply Glue Around the Counterbore

• Use wood glue (such as Tightbond) around the sides of the counterbore.

• Apply a thin, even coat to ensure adhesion without excess squeeze-out.

• Do not fill the entire hole with glue; only coat the walls of the counterbore.

### Step 4 — Insert and Seat the Hardwood Plug

• Insert the species-matched plug with the grain oriented correctly.

• Tap into place with a wood block or scrap board to avoid denting.

• Ensure the plug sits slightly proud, then tap until fully flush.

### Step 5 — Sand (If Needed)

• Most plugs seat flush without sanding.

• If minor proudness remains, lightly sand to blend.

• Once complete, the plug should disappear visually into the board surface.

## Recommended Use Cases and Best Practices

Starter and Perimeter Boards

These areas require face fastening, making Pro Plugs ideal for:

• Deck edges

• Picture frames

• Border boards

• Boards installed against walls or obstructions

Stairs and Risers

Stair treads and risers cannot accept clips or edge screws, making the Pro Plug System the preferred fastening method.

Fascia and Trim

Fascia boards often need:

• Stainless screws

• Glue-set plugs

• Additional expansion control

Fascia must not be installed without relief cuts or furring (see Fascia section in BWD hardwood education), but Pro Plugs provide the necessary hidden fasteners.

## Handling Hardwood Boards for Plug Installations

End Sealing

• Every cut end must be sealed with end wax immediately after cutting.

• Prevents checking and premature cracking.

Easing the Ends

• Sand or route a small radius on cut ends to match factory edges.

• Recommended for picture frames and butt joints.

Spacing

Maintain standard hardwood spacing:

• 1/8″ typically

• 3/32″ to 3/16″ acceptable

• 1/16″ at butt joints for visual uniformity

Stainless Steel Only

Using non-stainless screws causes:

• Black staining

• Oxidation rings

• Long-term surface discoloration

## Pro Plug System and Seasonal Board Movement

Brazilian hardwoods expand across their width and contract as moisture changes. Pro Plugs allow natural movement when screws are installed at the correct depth and properly predrilled.

Benefits:

• Reduces surface cracking

• Distributes mechanical holding force

• Prevents cupping when combined with proper airflow

## Maintenance After Installation

A deck installed with Pro Plugs requires:

• Routine cleaning

• Optional oiling with hardwood oil

• Occasional inspection for plug movement

• Minor plug replacement if plugs loosen over time

Plugs typically last the life of the deck when installed correctly.

## Safety & Tooling Requirements

• Wear eye, ear, and dust protection

• Use carbide-tipped blades for cutting hardwoods

• Set up cutting areas downwind to reduce dust exposure

• Ensure drill bits remain sharp to avoid burn marks

## Limitations of the Pro Plug System

Pro Plugs are not intended for:

• Structural load-bearing attachment

• Situations requiring hidden fasteners across the entire deck

• Grooved boards where clips can be used instead

They complement, but do not replace, hidden fastening systems like:

• Clips for grooved boards

• Edge screws (CAMO) for square-edge boards

• Undermount systems (DeckMaster)

## Contact Information

Brazilian Wood Depot
6770 Buford Highway NE
Atlanta, GA 30340

Phone: 770-242-0045
Email: sam@bwdepot.com

Customers are encouraged to leave a 5-star Google review after completing their project.

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