Uh-Oh, Jim's got it too......the plug building bug.
Question #1. I usually use a pair of needle nosed pliers with round tips, a pair of regular pliers, and a vise....put nose loop in vise (with plug on it), bend the wire 45 degrees down, then bend the loop up and around untill the tail of the wire points down. At this point, grab the loop with the regular pliers and the free end of the wire with the needlenose, and begin wrapping the wire around itself till you are up against the back of the plug....go as far as you can go, tighter is better than looser. Below is an exaggerated picture of tail loop wraps. Where the arrow points to, wrap it as far as you can, these last loops tension the wire to hold all the pieces together, and keep the wire from spinning in the plug.
Question #2. I use siwash with some bucktail tied on.....1 treble is enough chances to poke holes in myself.
Question #3. I use 2 part epoxy for the weights, and I seal the entire lure with epoxy after I have the wire done. I'm working on 3 of those kits right now Jim, my basic order of operations is:
1. Fit all pieces together as a test fit, do any trimming as required to get the fit I want....an example is to fit the lip into the slot, and make sure it fits all the way against the face of the plug....the bend in the lip is round, and the end of the slot is square, I sand or file the square corner off till the lip sits all the against the face of the plug. I had one plug that needed the slot cut deeper, a hacksaw blade did that.
2 After all the parts fit, seal the wood with something. I use a 60/40 mixture of boiled linseed oil/mineral spirits, dip the plug under for 2 minutes, remove and wipe dry, dispose of all rags OUTSIDE somewhere, they may spontaneously combust as they dry (linseed oil). Let plugs dry completely (several days)
3 Lightly sand, and prime plug with a couple of coats of something, to fill and provide a good base for paint.
4 Lightly sand and apply some funky-ass paint in the color scheme of your choice. Make it scream "Eat Me"! Let dry till you can't stand it anymore.
5 Install grommets at front, rear, and belly, I usually epoxy the belly grommet in, the wire will hold the front and rear. Install the wire, (make sure to run wire thru swivel for belly hook!), make tail loop wraps tight enough to keep the wire from spinning in the plug.
6 Epoxy in the eyes. After the epoxy dries, mix up a larger batch of epoxy to clear coat the entire plug. Some guys like to clear the plug before the wire is done, I like to clear after the wire is in, I seal up both ends of the wire, around the lip, everywhere I can, to try to keep water out. A short piece of a drinking straw will keep epoxy away from the belly swivel. Coat the entire plug with epoxy (the general opinion is to use Devcon 2 ton 30 minute epoxy for this step, I can't find that so I use Loctite 30 minute....works OK). Flip the plug around several times till you're sure the epoxy has set up, then hang to dry.
7 Finally, hang some hooks on the bitch and go catch large!!!!!!!!