Materials: 

• Dremel or equivalent or small round file
• PVC pipe (size to be determined)
• ¼ inch Para cord or equivalent
• Lighter
• Knife

This is a simple method for making scupper plugs.  I wanted to make some scupper plugs for the T-120, and back-ups for my Tarpon.  I got some packing foam from my brother-in-law that is used to pack computers.  It is the same stuff that pool noodles are made from, but mine was free and white. 

First thing you need to do is determine the diameter of the plugs needed.  For the T-120, you need 11/4 inch PVC.  If your scupper holes are bigger, then get bigger PVC.  You only need a small section of PVC (at least a foot long though), then you sharpen the inside edge with a round file or a Dremel tool with a grinding bit.  Sharpen it enough to get a good edge.  Then drive the PVC into the foam with a twisting motion or use a rubber mallet.  You will basically be coring the foam like an apple.  When you pull out the PVC, you will have a section of foam lodged in the pipe.  Pull it out, and then cut to the desired length (1 ½ to 2 inches).  The foam will be a little rough, so take a lighter set at maximum flame and lightly run the flame over all surfaces of the plug.  As a word of caution, you may want to hold the foam with pliers or impale it with something while you flame it.  The foam gets “melty”, and although I didn’t have a problem doing it by hand, I don’t want anyone getting melted foam cooked on to his or her skin.  You also only need to lightly and quickly run the flame over it.  You will feel it smooth out and you can press it down while it is still warm.

The only thing left is to drive the cord through the center and put a knot on the end so the plug stays attached.  You don’t even have to attach a cord if you are just going to keep the plugs in.  As in the case of the T-120, the second holes under the knees is not really necessary, so you can plug them and leave them in.

Making these plugs is cheap and easy.  If you lose them, you can easily replace them.  I made about eight sets in 20 minutes or so.