Carved Plug

• 1
  Layers of MDF begin to form the basic shape.an ancient step pyramid image by Elmo Palmer from Fotolia.com
  
  Cut out pieces of MDF to build up a rough shape of the finished object. For example, if your finished object is a pyramid, you would begin by making a step pyramid.
  
  
• 2). Glue the various layers together. Use clamps to hold them tight while the glue dries.
  
  
• 3). Use saws and carving tools to refine the plug into the finished shape. Don't worry about adding a lot of detail, it will not be captured in the plastic.
  
  
• 4). Drill holes in sunken areas to ensure that the plastic gets sucked down (for example in the eye sockets of a face shape).
  
  

Build the Plug

• 1). Cut out the various pieces of the plug. This technique works best for geometric shapes, but not well for curves and organic forms.
  
  
• 2). Trim the edges to whatever angles are needed to form a seamless joint. For example, a pyramid made of four triangles would need to have their edges cut at a 76-degree angle. The more complex the shape, the harder this cutting is to accomplish.
  
  
• 3). Glue the pieces together, and further secure them with wood screws. If the plug requires larger screws, drill pilot holes first to prevent the MDF from splitting.
  
  
• 4). Fill in the screwdriver hole in each screw depression with wood putty. Also use wood putty in any seams that are not perfect.
  
  
• 5). Sand the wood putty smooth.
  
  
• 6). Round the edges if desired.