Bladed plug cutting tool and related method of use

A plug cutting tool configured to produce plugs having an aesthetic exterior surface common to a donor board from which the plug is produced, the tool comprising:

• a tool longitudinal axis;
• a carrier that rotates about the tool longitudinal axis;
• and
• a blade joined with the carrier, the blade including a first cutting edge moveable along a first extension axis transverse to the tool longitudinal axis as the blade rotates about the tool longitudinal axis,
• wherein the first cutting edge moves closer to the tool longitudinal axis as the first cutting edge bores a groove in a donor board,
• whereby the first cutting edge is configured to advance into the donor board to produce the groove surrounding a plug having a plug face, a plug bottom, and a plug sidewall inwardly tapered from the plug face to the plug bottom so that the plug face has a greater dimension than the plug bottom.

A method of producing a plug for installation in a board, the method comprising:

• rotating a tool, including a cutting edge about a tool longitudinal axis;
• engaging the cutting edge against a donor board to penetrate a donor board face of the donor board, the donor board face including an aesthetic exterior surface;
• boring a groove below the donor board face with the cutting edge, the plug retaining the aesthetic exterior surface along a plug face in a plug upper portion, the plug including a plug sidewall facing the groove, and a plug lower portion located below the plug upper portion;
• and
• advancing the cutting edge along a first extension axis that is transverse to the tool longitudinal axis, while rotating the tool, to taper the plug so that the plug is inwardly tapered between the plug upper portion and the plug lower portion,
• wherein the plug face includes a first dimension greater than a second dimension of the plug lower portion.