Plugs and Caps for Blasting and Coating

My plugs have arrived!  I ordered the 110 piece silicone plug and cap kit from Eastwood.com to finish prepping Ms. Rusty for bead blasting and powder coating.  This post will cover the contents of the kit and the sizes of each plug/cap, since the Eastwood site doesn’t provide this information.
Here is the complete kit contents as it arrived from Eastwood:

Here are some photos of all the plugs and caps in the kit for comparison purposes.

All the plugs in the kit are tapered so they can fill a range of hole sizes. The smallest plugs (green) have a diameter of 1/8” at the smallest end and taper to 1/4” at the long end and are 3/4” long.  All the other plugs are 1” long.  Here is a table of all the plug sizes

Color	Small End	Large End
Green	1/8”	1/4”
Red	1/4”	3/8”
Black	3/8”	9/16”
White	1/2”	21/32”
White	13/16”	1”

Next are the caps. They differ from the plugs in that they are the same diameter their entire length, and they are hollow on the inside. For each of the caps I’ll list the inner diameter (ID), outer diameter (OD), and length (L).

Color	ID	OD	L
Gray	1/8”	3/16”	13/16”
White	5/32”	1/4”	1 1/8”
Blue	3/16”	9/32”	1 5/32”
Green	1/4”	11/32”	1 3/16”
Yellow	3/8”	1/2”	1 1/4”
Green	1/2”	9/32”	1 3/4”

There were 10 pieces of each size plug and cap, so hopefully this will give me enough variety to protect most the smooth machined holes and screw holes in Ms. Rusty.  I already know there are a few holes that are smaller than 1/8” diameter, so I plan on using some wood and/or bamboo skewers for those holes. 

The next post will finish up the protection of Ms. Rusty’s delecate surfaces.  Unfortunately, this prep work is taking much longer than I anticipated, but it should be worth it in the end.  I guess we’ll find out soon enough :)