How To Make A Push Block For A Table Saw: Safe Woodworking

What is a push block for a table saw? A push block for a table saw is a safety tool designed to help you guide wood through the blade while keeping your hands a safe distance away. This blog post will walk you through how to build your own, promoting table saw safety and accurate cuts.

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Why You Need a Push Block for Table Saw Safety

The table saw is a powerful and versatile tool, but it can also be dangerous. Table saw safety depends on respecting its power and using appropriate safety equipment. One of the most crucial pieces of safety equipment is a push block. A push block provides a safe way to advance wood past the blade, preventing your hands from getting too close. It significantly reduces the risk of kickback and other injuries. A good woodworking push stick or shop-made push block is an investment in your safety and peace of mind.

The Dangers of Working Without a Push Block

• Close Proximity to the Blade: Your hands get dangerously close to the spinning blade, especially when making narrow cuts.
• Increased Risk of Kickback: If the wood binds or pinches the blade, it can be violently thrown back towards you.
• Loss of Control: It’s harder to maintain a steady, even feed rate without a push block, leading to uneven cuts.

Benefits of Using a Push Block

• Enhanced Safety: Keeps your hands a safe distance from the blade.
• Improved Control: Allows for a more consistent and controlled feed rate.
• Greater Accuracy: Helps produce cleaner and more precise cuts.
• Reduced Fatigue: Less strain on your hands and arms, especially during longer cuts.

Types of Push Blocks

There are several types of push blocks, each designed for different cutting tasks and personal preferences. Each type has unique strengths, making them suited for specific applications.

Push Blocks vs. Push Sticks

A woodworking push stick is typically a simpler, thinner tool used for applying pressure to the side of the workpiece. In contrast, a push block generally has a larger surface area and often features a heel or other mechanism to grip the end of the board, allowing you to push it completely past the blade. Think of a push stick as more for guiding, while a push block is for both guiding and pushing.

Common Push Block Designs

Design	Description	Best For
Standard Push Block	A flat block with a handle and a high-friction surface.	General-purpose use, ripping lumber.
L-Shaped Push Block	Features a 90-degree angle, allowing you to hook the back edge of the workpiece.	Pushing narrow pieces past the blade, preventing kickback.
Long Push Block	An extended version for long cuts, providing extra stability and control.	Ripping long boards, maintaining consistent pressure.
Gripper Push Block	Uses a rubber or textured surface to provide a strong grip on the workpiece.	Working with slippery materials or when maximum control is needed.
Adjustable Push Block	The push block is adjustable to fit different cutting tasks and personal preferences.	Versatile, adaptable to a variety of cuts

Choosing the Right Design

The best push shoe design for you depends on the type of woodworking you do and the kinds of cuts you frequently make. For general use, a standard or L-shaped push block is a good starting point. If you often work with long boards, consider a long push block. For slippery materials, a gripper push block is ideal.

Materials and Tools Needed to Build a Push Block

Building a DIY push block is a simple and rewarding project. Here’s what you’ll need:

Materials

• Wood: Use hardwood like maple, oak, or birch for durability. 3/4″ thickness is ideal. Softwoods like pine are usable, but won’t last as long.
• Screws: #8 or #10 wood screws, 1 1/4″ to 1 1/2″ long.
• Non-Slip Material (Optional): Rubber sheet, sandpaper, or adhesive-backed non-slip pads.
• Wood Glue: For added strength.

Tools

• Table Saw: To cut the wood pieces to size (ironically).
• Drill/Driver: For drilling pilot holes and driving screws.
• Measuring Tape: For accurate measurements.
• Pencil: For marking cut lines.
• Clamps: To hold pieces together while the glue dries.
• Safety Glasses and Hearing Protection: Always wear these when working with power tools.
• Sanding Block or Sandpaper: To smooth any rough edges.

Step-by-Step Guide: Build Push Block

This guide focuses on building a standard L-shaped push block, a versatile design suitable for many table saw operations.

Step 1: Prepare the Wood

1. Cut the Pieces: Using your table saw (carefully!), cut the following pieces from your chosen hardwood:

   • Base: 4″ wide x 8″ long
   • Handle: 4″ wide x 6″ tall
   • Heel: 2″ wide x 4″ tall
     2. Sand the Pieces: Smooth all edges and surfaces with sandpaper or a sanding block. This will make the push block more comfortable to use and prevent splinters.
     

Step 2: Assemble the Handle

1. Attach the Handle to the Base: Apply wood glue to the bottom edge of the handle. Position the handle on the base, centered width-wise and set back 1″ from the front edge.
2. Clamp and Screw: Clamp the handle to the base. Drill pilot holes through the base into the handle. Drive screws through the pilot holes to secure the handle.

Step 3: Attach the Heel

1. Position the Heel: Apply wood glue to the bottom edge of the heel. Position the heel on the back edge of the base, flush with the bottom.
2. Clamp and Screw: Clamp the heel to the base. Drill pilot holes through the base into the heel. Drive screws through the pilot holes to secure the heel.

Step 4: Add Non-Slip Material (Optional)

1. Cut the Material: Cut a piece of non-slip material to fit the bottom of the base.
2. Attach the Material: Apply adhesive or glue to the back of the non-slip material and attach it to the base.

Step 5: Final Touches

1. Check for Sharp Edges: Ensure there are no sharp edges or corners that could catch on the workpiece or blade.
2. Test the Push Block: Before using the push block on a real project, test it on a scrap piece of wood to ensure it functions properly.

Detailed Plans:

Part	Dimensions	Quantity	Material
Base	4″ x 8″ x 3/4″	1	Hardwood
Handle	4″ x 6″ x 3/4″	1	Hardwood
Heel	2″ x 4″ x 3/4″	1	Hardwood

Note: Dimensions are suggestions. Feel free to customize based on your needs.

Safe Cutting Techniques with a Push Block

Using a push block correctly is just as important as having one. Here are some safe cutting techniques to keep in mind:

• Always Use a Push Block for Narrow Cuts: When cutting pieces that are narrower than your hand width, a push block is essential.
• Maintain a Firm Grip: Keep a firm, steady grip on the push block.
• Keep the Push Block Flat: Ensure the push block remains flat on the table saw surface.
• Never Reach Over the Blade: Avoid reaching over the blade to retrieve the workpiece. Turn off the saw and wait for the blade to stop before retrieving the wood.
• Use a Featherboard (Optional): A featherboard can provide additional support and control, especially when ripping long boards.
• Avoid Cutting Freehand: Never attempt to cut freehand without using the fence and a push block.
• Inspect Your Materials: Before you use the push block, inspect the wood that will be cut for any defects.
• Think Ahead: Consider all cutting needs before you begin

Maintaining Your Push Block

Proper maintenance will extend the life of your push block and ensure it continues to function safely.

Regular Inspections

• Check for Damage: Regularly inspect your push block for cracks, splits, or loose screws.
• Replace Worn Parts: Replace any worn or damaged parts immediately.
• Clean the Surface: Keep the surface of the push block clean and free of sawdust and debris.

Replacing the Non-Slip Material

If the non-slip material wears out, replace it with a new piece. This will ensure the push block maintains a good grip on the workpiece.

Customizing Your Push Block

Once you’re comfortable with the basic design, you can customize your push block to suit your specific needs.

Adding a T-Track

Installing a T-track on the push block allows you to attach various accessories, such as adjustable fences or hold-downs.

Creating a Multi-Purpose Push Block

Design a push block with multiple features, such as a built-in miter gauge slot or a detachable handle.

Adjusting the Size and Shape

Experiment with different sizes and shapes to find a design that fits your hand comfortably and provides optimal control.

Additional Safety Tips for Table Saw Use

Beyond using a push block, here are some general table saw safety tips:

• Read the Manual: Familiarize yourself with the table saw’s manual and safety instructions.
• Wear Safety Glasses and Hearing Protection: Always protect your eyes and ears when operating the table saw.
• Use a Riving Knife or Splitter: These devices prevent the workpiece from pinching the blade and causing kickback.
• Stand to the Side of the Blade: Avoid standing directly behind the blade, where you could be hit by kickback.
• Keep the Blade Sharp: A dull blade is more likely to cause kickback.
• Use Proper Lighting: Ensure your work area is well-lit.
• Avoid Distractions: Concentrate on the task at hand and avoid distractions.
• Unplug the Saw When Changing Blades or Making Adjustments: This prevents accidental starts.

Interpreting Table Saw Jigs and Accessories

While a push block is a fundamental safety tool, other table saw jigs and accessories can further enhance your woodworking experience. Consider exploring featherboards, miter gauges, and tenoning jigs to expand your capabilities and improve the precision of your cuts.

Frequently Asked Questions (FAQ)

Q: Can I use a piece of scrap wood as a push block?
A: While you can use scrap wood in a pinch, it’s not recommended as a long-term solution. A properly designed push block offers a better grip, more control, and greater safety.

Q: What is the best material for a push block?
A: Hardwoods like maple, oak, or birch are ideal because they are durable and resistant to wear.

Q: How often should I replace my push block?
A: Replace your push block if it becomes damaged, worn, or if the non-slip material loses its grip.

Q: Do I need different push blocks for different types of cuts?
A: It depends on the types of cuts you make most often. A standard push block is suitable for general use, but specialized push blocks may be helpful for narrow cuts, long cuts, or working with slippery materials.

Q: What is a featherboard, and how does it work with a push block?
A: A featherboard is a safety device that provides additional support and control by applying pressure to the workpiece against the fence. Using a featherboard in conjunction with a push block can improve accuracy and reduce the risk of kickback.