How To Make a Push Block For a Table Saw: Save Money

A push block for a table saw is a woodworking safety tool used to guide material past the blade while keeping your hands a safe distance away. Yes, you can make one yourself! Instead of buying a pricey push block, you can build your own DIY push block for a fraction of the cost. This article will teach you how to create several types of shop-made push blocks that will significantly improve your table saw safety and allow you to confidently tackle your woodworking projects.

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Why Use a Push Block? Table Saw Safety First

Table saw safety is paramount. A table saw is a powerful tool, and accidents can happen in a split second. Using a push block is a vital part of safe sawing techniques because it provides a controlled way to feed wood through the blade. Here’s why push blocks are indispensable:

• Keeps Hands Away From the Blade: The primary function of a push block is to increase the distance between your hand and the spinning blade. This is crucial, especially when cutting smaller or narrower pieces of wood.
• Improved Control: Push blocks provide a larger, more stable surface to grip, allowing for better control over the workpiece. This is especially useful when cutting thin or uneven stock.
• Reduces Kickback Risk: A good push block helps maintain constant pressure on the wood, reducing the likelihood of kickback. Kickback occurs when the blade catches the wood and throws it back toward the operator, which can be extremely dangerous.
• Consistent Cuts: By maintaining consistent pressure and control, push blocks help you achieve cleaner, more accurate cuts.
• Protect Your Hands: In addition to preventing contact with the blade, push blocks can protect your hands from splinters and debris.

Different Types of Push Blocks: Choosing the Right One

There are many different push block designs available, each with its strengths and weaknesses. The best push block for you will depend on the type of cuts you make most often and your personal preferences. Let’s explore some popular options:

The Simple Push Stick Alternative

A push stick is the most basic push block alternative. It’s a simple piece of wood, usually with a notch or handle at one end.

• Pros: Easy to make, inexpensive.
• Cons: Limited control, less effective for thin stock, less hand protection.

Feature	Description
Material	Scrap wood (plywood, hardwood)
Construction	Simple cut and shape
Best For	Wider stock, basic cuts
Skill Level	Beginner
Hand Protection	Minimal

The Standard Push Block

This is a more substantial push block with a handle and a non-slip base. It is a versatile woodworking safety tool suitable for various table saw operations.

• Pros: Better control than a push stick, improved hand protection, versatile.
• Cons: Requires more materials and construction time.

Feature	Description
Material	Plywood, hardwood, rubber or sandpaper for the base
Construction	More complex, requires cutting, gluing, and possibly screwing
Best For	General use, medium to small stock
Skill Level	Intermediate
Hand Protection	Good

The Long Push Block/Paddle

This push block is elongated and often includes a comfortable handle, giving extended reach and control, especially when cutting larger workpieces or full sheet goods on the table saw.

• Pros: Excellent for sheet goods, keeps hands far from the blade.
• Cons: Can be bulky, not ideal for smaller workpieces.

Feature	Description
Material	Plywood, hardwood
Construction	Similar to a standard push block, but longer
Best For	Large sheet goods, long cuts
Skill Level	Intermediate
Hand Protection	Excellent

The Gripper Push Block

The gripper push block is specifically designed for enhanced hold and feed control, featuring a durable gripping surface that firmly secures the material during cutting operations on the table saw.

• Pros: Excellent grip, good for slippery or uneven stock.
• Cons: Can be more expensive to make (depending on grip material), grip can wear out over time.

Feature	Description
Material	Plywood, hardwood, specialized grip material (e.g., rubber, non-slip tape)
Construction	Involves adding a secure gripping surface
Best For	Slippery materials, challenging cuts, maintaining consistent feed rate on the table saw
Skill Level	Intermediate to Advanced
Hand Protection	Good

DIY Push Block: A Step-by-Step Guide

Here’s a step-by-step guide to making a standard push block. Remember to always prioritize table saw safety and double-check all measurements before cutting. Here are some push block plans:

Materials:

• 3/4″ Plywood (or other suitable scrap wood)
• Wood glue
• Screws (optional, for added strength)
• Sandpaper (80-grit and 120-grit)
• Non-slip material (rubber, sandpaper, or non-slip tape)

Tools:

• Table saw
• Miter saw (optional)
• Drill
• Screwdriver
• Clamps
• Measuring tape
• Pencil

Instructions:

Step 1: Cut the Base

1. Cut a piece of plywood to the following dimensions: 4″ wide x 8″ long. This will be the base of your push block.

Step 2: Cut the Handle Support

1. Cut two pieces of plywood to the following dimensions: 2″ wide x 6″ tall. These will support the handle.

Step 3: Cut the Handle

1. Cut a piece of plywood to the following dimensions: 2″ wide x 4″ long. This will be the handle.

Step 4: Assemble the Handle Support

1. Apply wood glue to the bottom edges of the handle support pieces.
2. Attach the handle support pieces to the base, positioning them 1″ from each side.
3. Clamp the pieces together and let the glue dry for at least 30 minutes.
4. (Optional) For added strength, drive screws through the base into the handle supports.

Step 5: Attach the Handle

1. Apply wood glue to the top edges of the handle support pieces.
2. Attach the handle to the top of the handle supports, centering it.
3. Clamp the pieces together and let the glue dry for at least 30 minutes.
4. (Optional) For added strength, drive screws through the handle into the handle supports.

Step 6: Add a Non-Slip Base

1. Cut a piece of non-slip material (rubber, sandpaper, or non-slip tape) slightly larger than the base of the push block.
2. Apply adhesive to the back of the non-slip material.
3. Attach the non-slip material to the bottom of the base, ensuring it is securely bonded.

Step 7: Sand the Push Block

1. Sand all edges and surfaces of the push block with 80-grit sandpaper to remove any sharp edges or splinters.
2. Finish sanding with 120-grit sandpaper for a smooth finish.

Step 8: Test and Adjust

1. Test the push block on your table saw to ensure it provides a comfortable and secure grip.
2. Make any necessary adjustments, such as adding more non-slip material or reshaping the handle.

Enhancing Your Push Block Design: Customization and Features

Once you’ve mastered the basic push block, you can customize it to better suit your needs. Here are some ideas for push block design enhancements:

• Angled Handle: An angled handle can provide a more natural and comfortable grip.
• Contoured Grip: Shape the handle to fit your hand for improved ergonomics.
• Replaceable Grip: Design the push block with a replaceable grip surface, so you can easily replace it when it wears out.
• Dust Collection: Incorporate a dust collection port into the push block design to help keep your workspace clean.
• Clear Acrylic: Use clear acrylic for the base to improve visibility of the blade and workpiece.

Tips for Using a Push Block Effectively

Using a push block correctly is just as important as having one. Here are some tips for using a push block effectively and maximizing table saw safety:

• Choose the Right Push Block: Select the appropriate push block for the type of cut you are making.
• Maintain Constant Pressure: Apply consistent, even pressure to the push block throughout the cut.
• Keep Your Body Out of the Line of Fire: Stand to the side of the blade, not directly behind it.
• Never Reach Over the Blade: Always use a push block or push stick to guide the wood past the blade.
• Use Two Push Blocks When Necessary: For very narrow or thin stock, use two push blocks simultaneously for maximum control.
• Inspect Your Push Block Regularly: Check for wear and tear, and replace the push block if it is damaged.
• Practice: Practice using the push block on scrap wood before cutting your final piece.

Troubleshooting Common Push Block Issues

Even with the best push block and technique, you may encounter some issues. Here are some common problems and how to solve them:

• Slipping: If the push block is slipping, make sure the base is clean and dry. You may also need to replace the non-slip material.
• Lack of Control: If you feel like you don’t have enough control, try using a larger push block or one with a better grip.
• Kickback: If you experience kickback, stop immediately and re-evaluate your technique. Make sure you are using the correct blade, the blade is sharp, and you are feeding the wood at the correct speed.
• Push Block Damage: If your push block becomes damaged, replace it immediately. Do not use a damaged push block.

Other Woodworking Safety Tools for Table Saw

While push blocks are essential, they are just one piece of the table saw safety puzzle. Here are some other woodworking safety tools that every woodworker should use:

• Blade Guard: The blade guard is a clear plastic shield that covers the blade. It prevents accidental contact with the blade and helps contain dust and debris.
• Riving Knife/Splitter: The riving knife or splitter is a metal piece that sits behind the blade and prevents the wood from pinching and causing kickback.
• Featherboards: Featherboards are flexible strips of wood or plastic that hold the wood against the fence or table, providing consistent pressure and preventing movement.
• Push Sticks: As described earlier, push sticks provide a safe way to push narrow pieces of wood past the blade.
• Safety Glasses: Safety glasses protect your eyes from flying debris.
• Hearing Protection: Hearing protection prevents hearing damage from the loud noise of the table saw.
• Dust Mask: A dust mask protects your lungs from harmful wood dust.

Fathoming the Value of Shop-Made Push Block

Making your own push block offers several advantages beyond cost savings. A shop-made push block allows for customization, ensuring it fits your specific needs and preferences. The ability to modify the design, materials, and grip enhances the overall experience and makes projects safer and more efficient. Crafting your own push block becomes a valuable learning experience, reinforcing safe sawing techniques and improving your skills in jig making, further enriching your table saw safety practices.

Frequently Asked Questions (FAQ)

• Q: What is the best material for a push block?
  • A: Plywood is a good all-around choice for push blocks. It’s strong, stable, and readily available. Hardwoods can also be used for added durability. For the grip, rubber, sandpaper, or non-slip tape are all effective options.
• Q: Can I use a push stick instead of a push block?
  • A: While a push stick is better than nothing, a push block generally offers better control and hand protection. Use a push stick for wider stock but opt for a push block when working with narrower pieces.
• Q: How often should I replace my push block?
  • A: Replace your push block as soon as it shows signs of wear or damage, such as cracks, splinters, or a worn-out grip.
• Q: What is the most important feature of a push block?
  • A: The most important feature of a push block is a secure grip. You need to be able to maintain a firm hold on the push block to control the wood safely.
• Q: Can I buy a pre-made push block?
  • A: Yes, you can buy pre-made push blocks. However, making your own is a cost-effective and customizable alternative.

By following these tips and instructions, you can create a safe and effective push block that will help you get the most out of your table saw while protecting your hands. Prioritize table saw safety above all else!