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Plugging Tips

The tips in this section will help you pour plug that will match the ball's original color and never crack out. Click the links below to skip to the section of interest.

DBA/Ultima Plugging Tips
DBA/Ultima Q&A
DBA/Ultima Color Mixing Guide
DBA/Ultima Color Mixing Sequence
Wizard Ball Plug Instructions & Tips

DBA’s Ball Plugging Tips

Follow these steps to insure a perfect plug every time:

  • Maintain a room, ball and chemical (ball plug and color kit) temperature of 72 - 78 degrees. Since ball plug is temperature sensitive, it is very important to maintain this temperature!
  • Mix plug slowly for 2 minutes in a figure 8 pattern. Occasionally scrape the sides and bottom of the cup to insure that the plug is mixed thoroughly.
  • Use a stop watch or clock to time the amount of stirring. It is important that the plug be mixed for 2 full minutes to complete the reaction of the compound and hardener.
  • When coloring the plug, add the color to the compound only. Add the hardener after the color has been matched to the ball. This will prevent overmixing or having the plug cure before a color match is made.
  • Plug large holes in 2 stages. Plug one half of the hole and let it cure completely. After this plug is hard and cool to the touch, plug the second half of the hole. This procedure helps prevent too much heat from being generated by the plug and causing it to crack.
  • When plugging small holes, mix the plug and leave it in the cup until it becomes very warm, then pour immediately into the hole.
  • Allow the plug to cure completely before routering and sanding. This helps prevent the plug from shrinking after the plug has been cut down.
  • Pour excess uncured plug into miniature ice cube trays for later use. When the plug cure, use the cubes to fill large holes. The plug cubes will not affect the curing of the liquid plug.
  • When preparing a ball to be plugged, drill out any bevel or large cracks around the perimeter of the hole. This will increase plug adhesion and reduce the possibility of edge chipping or separation. Lightly sanding near the top of the hole will also help create better adhesion.
  • Read and follow all manufacturer’s instructions on the label of the bottle. This applies to ball plug and color kits

DBA’s Ball Plug Question and Answers

  • What causes plug to chip/crack and how can I prevent it from happening??
    • Two of the main reasons plug will chip and crack are:  Room temperature above 80 degrees and/or the plug mass is too large, generating too much heat during cure. A temperature of 72-78 degrees (this applies to room, ball and chemicals) must be obtained for the plug to cure properly. Large holes should be plugged in two stages, allowing the first half of the plug to cure completely before
  • What are the causes of plug curing too slow and what can be done to insure a solid cure??
    • Slow curing plug is caused by defective pumps, plug that hasn’t been mixed long enough, room temperature below 70 degrees or small masses of plug that don’t generate enough heat to provide a thorough cure. The following are solutions to these examples:
      • Test and replace pumps if necessary
      • Mix the plug for a full 2 minutes. Use a stop watch if necessary.
      • Make sure the room temperature is between 72-78 degrees
      • When plugging small holes, mix the plug and leave it in the cup until the plug becomes very warm. Pour immediately into the hole.
  • How can I plug large holes without the plug cracking??
    • Plug the hole in 2 stages. Plug one half of the hole and let it cure completely. After this plug is hard and cool to the touch, plug the 2nd half of the hole. This is especially true for large holes in urethane balls, since the thicker shells of urethane balls tend to trap heat. This procedure helps prevent too much heat from being generated by the plug and causing it to crack.
  • How can I make sure that my pumps are dispensing the correct amount of material??
    • Use the following test procedure:
      • 1. Use 2 identical cups
      • 2. Dispense 1 plunge of compound into one cup.
      • 3. Dispense 3 plunges of hardener into the 2nd cup.
      • 4. Place cups side by side on a level surface
      • 5. Fluid levels in the cups should be identical.
      • 6. If the fluid is not at the same level, the pumps are not dispensing the proper amount of material. Replace pumps to avoid plug curing problems.
  • Is there anything I can do to reduce air bubbles in the plug??
    • Air bubbles usually indicate that the plug has been mixed too vigorously. Mix the plug slowly in a figure 8 pattern, occasionally scraping sides and bottom of the cup. Do not pour plug into the center of the hole. This procedure tends to trap air bubbles at the bottom. Pour the plug slowly, using the stir stick as a guide so the plug runs down the wall of the hole.  If air has already been entrapped while mixing, allow plug to stand in the mixing cup for approximately 10 minutes. The larger surface area in the cup will allow the air bubbles to escape more easily.
  • How can I prevent a plug from shrinking after it’s been cut down and finished??
    • Plug will shrink after being cut down or finished because it has not completed the curing process. The frictional heat created when finished the partially cured plug causes a secondary reaction and swelling in uncured epoxy.  The plug then shrinks as it cools. This usually occurs in cold weather or when plugging smaller holes.  To prevent this from happening, place a 60-75 watt light 3-4” away from plug material for 1-2 hours immediately after the plug is poured. This will prevent shrinkage in cold weather. When plugging smaller holes, leave plug in the cup until it becomes warm, then pour in the hole.
  • What causes separation between the seam of the plug and the ball and what steps can I take to prevent it??
    • Plug separation is caused by the interior of the hole not being completely clean or by improper or inadequate plug mixing. Clean the hole’s interior with a fast drying solvent such as acetone before plugging. This helps insure good adhesion. For proper mixing, remember to follow manufacturer’s instructions. Light sanding near the top of the hole will also help create a better adhesion.
  • Is it safe to use heat lamps to help cure the plug in cold weather??
    • Yes, if care is taken not to overheat the plug. If heat lamps or other heating devices are used, be certain not to leave them unattended.
  • Is it safe to mix regular 321 Pro Plug Compound with Ultima Hardener and vice versa??
    • Mixing 2 different types of plug is NOT recommended. Curing problems may occur due to the difference in formula.
  • Do I have to get new pumps if I’m switching ball plug, or can I just take the pumps out of the old ball plug and put them in the new??
    • Again, this is not recommended. New pumps should be purchased to avoid the possibility of an incorrect ratio between compound and hardener.

DBA’s Color Mixing Guide

The following are suggested formulations designed to give a wide variety of basic colors. In some instances, precise color matches may require adjustment to these starting formulations.

Note that a given color mixed into new 321 Pro Plug Clear Compound and hardener will not change color as it cures into a hardened plug. It is not necessary to compensate for the “yellowing” effect created by other hardeners.

The suggested color formulations are based on one full plunge of Compound and one full plunger of Hardener. The numeral before the name of the color concentrate only demonstrates the number of drops of that color needed to blend the color to the left of the formulations

Blue #1

4 Blue

Blue/Violet

2 Blue/2 Violet

Blue/Green

2 Blue/2 Green

Red #2

4 Red

Red/Orange

2 Red/2 Orange

Red/Violet

2 Red/2 Violet

Yellow #3

4 Yellow

Yellow/Orange

2 Yellow/2 Orange

Yellow/Red

2 Yellow/2 Red

Black #4

4 Black

Black/Gray

2 Black

Green #5

4 Green

Green/Blue

2 Green/2 Blue

Green/Yellow

1 Yellow/2 Green

Violet #6

4 Violet

Violet/Blue

2 Violet/2 Blue

Violet/Black

2 Violet/2 Black

Caramel #7

4 Caramel

Caramel/Red

2 Caramel/2 Red

Caramel/Yellow

2 Caramel/2 Yellow

Orange #8

4 Orange

Orange/Blue

2 Orange/2 Blue

Orange/Turquoise

2 Orange/2 Turquoise

Orange/Caramel

2 Orange/2 Caramel

Cerise #9

4 Cerise

Cerise/Blue

2 Cerise/2 Blue

Cerise/Yellow

2 Cerise/2 Yellow

Turquoise #10

4 Turquoise

Turquoise/Blue

2 Turquoise/2 Blue

Turquoise/Green

2 Turquoise/2 Green

These color formulations are translucent and Natural Pearl is added for the Pearlizing effect. An opaque or solid color is made by increasing the number of color concentrate drops and adding a slight trace of white pigment concentrate. For example: a light blue solid color is 4 drops of blue, plus a trace of white pigment concentrate.

DBA’s Color Mixing Sequence

  1. One full plunge of Clear Compound
  2. One full plunge of Pro Plug Hardener
  3. Add Pearl or White Concentrate
  4. Add all color concentrate drops

Pump the Clear Compound and Hardener into a clean, non-wax paper cup. Using a narrow mixing stick, scoop up a small amount of the natural pearl (about the size of the small finger nail). Introduce the pearl into the plug mixture by first dabbing it repeatedly against one side of the cup to partially dissolve it before swirling it into the entire plug mixture.

COLOR DROPS MUST BE ADDED IN THE FOLLOWING MANNER:

  1. Hold the color concentrate bottle in an upright position and gently squeeze out a small portion of the air inside the bottle.
  2. Maintain this slight pressure while turning the bottle upside down (pointing straight down). Increase the squeezing pressure until the required number of drops have been dispensed. Each color concentrate bottle contains over 450 drops.
  3. Release the pressure to stop the flow of drops. Immediately upright the bottle in a smooth, even manner. Replace the cap.

Exactly follow this approach, the user can control the number of drops dispensed, because of the slight vacuum created by exhausting a portion of the air.

NOTE:  Always clean off any excess of color concentrate that may have run down the side of the dropper tip. This will assure proper size drops for future use. All container lids should be replaced after use to prevent possible evaporation.

Wizard Ball Plug by Ultimate Directions & Tips

  • Prepare holes carefully by first using your bevel sander to remove oil and unwanted debris from thumb and finger holes
  • Then use a drill bit to enlarge the opening of the hole large enough to remove any bevel, drilling down 1/4 to 3/8 of an inch. Vacuum out hole. Build area to be plugged by using a finger or thumb dam.
  • Important: When preparing Wizard Ball Plug, use non-waxed cups
  • Using pumps provided, put one plunge (1 oz) of Part “B” into the non waxed cup. At this point, add 15 drops of Ultimate’s black or red Wizcolor (all other colors use 12 drops) to Part “B” and mix thoroughly. Note:  If no color is added, plug will turn white.
  • Now add one plunge (1 oz) of Part “A” to Part “B” and stir for 30 to 40 seconds scraping the sides of the cup as you stir.
  • Pour mixture down the side of the hole until material is near the top of the dam. Wizard Ball Plug will begin to harden in 15 to 20 minutes.
  • Wizard Ball Plug can be cut, drilled, beveled and sanded in one hour.
  • To plug thumb and fingers, pour fingers first. Wait approximately 15 to 20 minutes, then turn ball up and pour thumb. One hour later, cut down fingers, then thumb.
  • NOTE:  Some chemicals tend to separate when left standing for periods of time. Improve performance by shaking before use.