My pro shop guy has a bit for the drill press to cut down plugs.  However, several years ago, he was using a router.  The router worked just fine, I think he changed to the drill press because the router was extremely loud.
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It IS next year!

A couple of things to consider with regard to plugging.

Plug has a shelf life, usually 1 year, although I guess you could go longer depending on your storage habits.  Quality may suffer.  Also, it tends to be sold it large quantities - relatively speaking.

I don't keep records of amounts used when I plug, but generally speaking you can do a full plug with 4 oz of plug - 2 of thumb and 1 for each finger.

1 gallon is 128 oz.  Most plug is a 2 gallon kit (1 to 1 mix is 1 gallon of each side), so that is enough to plug 64 balls.  That number sounds really high to me, so I'm sure my numbers are off.....just using that as an example.

I bought this kit 2 years ago, and have just opened the last bottle of resin: http://www.bowlingindex.com/store/merchant.mvc?Screen=PROD&Store_Code=BI&Category_Code=PST&Product_Code=PL-EPSKit

I haven't noticed any quality issues yet.

Occasionally you can find it sold in smaller amounts like 2 quarts.

A while back somebody was selling personal "routers" on ebay.  There were basically a tool similiar to this with a special shield:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=42831


Actually, I found it:  http://www.webspawner.com/users/bowling1/


I will say this - plugging may look easy, but it one of the hardest things to do correctly - meaning having a good color match, and a good, clean, smooth finish.

FWIW, at my local pro shops it's usually cheaper to have them plug and redrill a hole then it is to have them drill a hole.......not sure why that is?  Haven't checked in a while, but it used to be $40 for a full plug (up to 4 holes) and redrill, and $60 to drill a blank.  They also had a single price, something like $10 for x-hole, $10 per finger, and $20 for thumb.

Not sure how a shop would feel about cutting down and redrilling a ball that a customer plugged themselves.  That introduces a whole lot variables and risks if there is a problem.

File it down with a large file and then put it on a spinner and use a low grit.

Gene,

A spinner is a different thing. It's not really taking work away from a shop as, if you have any number of balls, they need regular maintenance and surface maintenance quite often these days, especially for all the fairly sensitive surfaces like 4000 grit.
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"None are so blind as those who will not see."

With todays coverstocks, plugging can become a pain when the oil in the ball starts to come out when the plug starts to "fire" and the plug dosen't bond to the ball!
Having a pro shop, I automatically put a ball to be plugged in my Revivor first! Of course, my charge for plug work is higher but in the long run saves xtra plug work and time.
Another problem you might run into if you plug yourself is keeping a fairly constant room temp and good mix precentages so the plug dosen't quick set and crack below the surface.
Matching colors will be the most fun you have and might find yourself replugging because you know you can do better!
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Use "IT" and BOWL UP A STORM!!

I will give you a tip with plugging, me personally in my shop when i plug a thumb hole 1 1/4 or bigger i will only plug half at a time due to sometimes not all the time if you fill the entire hole up a once you may see cracking. Play it safe and do half at a time.

Also someone said how their pro shop is cheaper to plug and redrill compared to drilling a fresh ball. The reason for this is local pro shops are there to make money and the internet kills us so we need to show that you really dont save alot buying online compared to our shop prices. When you plug a ball its usually an old ball so its not such a big deal to compare to the internet.

Yes there are pro shops who will drill for less but remember your getting what you pay for and what you are paying for is an expert to drill your ball. Someone with a better rep and more experience may be higher but prob. worth it. Your paying for knowledge and a trade that only few are good at.
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Rotogrip staff member

(The following is a trademarked idea) LOL, which means you cant use this Gene.....LOL

My driller and I are currently looking into a mobile drilling center...message me for details...LMAO!
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Its Hammer Time!!
HammerHead 4 Life