How To Make A Push Block For Table Saw: Simple & Safe

A push block for a table saw is a woodworking safety tool used to guide wood safely through the blade. Can you make one yourself? Absolutely! This article provides easy diy push block plans and explains how to create a shop-made push block to ensure safe ripping on a table saw. Using a push block is crucial for woodworking safety tools, protecting your hands and preventing kickback.

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Why You Need a Push Block

Using a table saw without the right safety gear is dangerous. A push block gives you more control and keeps your hands away from the blade. It’s a vital part of safe woodworking.

Protecting Your Hands

The most important reason to use a push block is to protect your hands. The blade is sharp and spins very fast. A push block lets you guide the wood without getting too close. This reduces the risk of injury.

Preventing Kickback

Kickback happens when the blade catches the wood and throws it back at you. This can cause serious harm. A push block helps keep the wood moving smoothly, reducing the chance of kickback. It gives you a better grip and more control.

Improving Accuracy

A push block helps you make straight, accurate cuts. It provides consistent pressure and guidance. This is important for getting good results in your woodworking projects.

Different Types of Push Blocks

There are many types of push blocks. Each one is designed for a specific task. Here are some of the most common:

• Standard Push Block: This is a basic push block with a handle and a non-slip base. It’s good for general use.
• Push Shoe: A push shoe has a wider base and is used for pushing wood through the blade.
• Long Rip Push Block: This type is longer and provides extra support for long pieces of wood.
• Heel Push Block: A heel push block has a heel that hooks over the end of the wood. This helps prevent kickback.

Choosing the Right Push Block Design

The best push block design depends on what you’re doing. Consider these things when choosing a design:

• Size: Choose a size that fits your hand comfortably. A larger block gives you more control.
• Grip: The grip should be comfortable and secure. A good grip prevents slipping.
• Material: Use a material that is strong and durable. Wood and plywood are good choices.
• Base: The base should be non-slip. Rubber or sandpaper can provide good traction.

Simple DIY Push Block Plans

Here’s how to make a basic push block. These diy push block plans are easy to follow and require simple materials.

Materials You’ll Need

• 3/4″ plywood or hardwood (approximately 6″ x 12″)
• 1″ thick scrap wood for the handle (approximately 2″ x 5″)
• Non-slip material (rubber or sandpaper)
• Wood glue
• Screws (1 1/4″)

Tools You’ll Need

• Table saw
• Drill
• Screwdriver
• Clamps
• Sandpaper
• Measuring tape
• Pencil

Step-by-Step Instructions

1. Cut the Base: Cut a piece of plywood or hardwood to 6″ x 12″. This will be the base of your push block.
2. Prepare the Handle: Cut a piece of scrap wood to 2″ x 5″. This will be the handle. Shape the handle for a comfortable grip. You can round the edges with sandpaper.
3. Attach the Handle: Apply wood glue to the bottom of the handle. Place the handle on the base, about 2 inches from the back edge. Secure the handle with screws. Drill pilot holes first to prevent splitting the wood.
4. Add Non-Slip Material: Cut a piece of rubber or sandpaper to fit the bottom of the base. Apply glue to the bottom of the base. Attach the non-slip material. This will give you better grip on the wood.
5. Sand the Edges: Sand all the edges of the push block. This will make it more comfortable to use. It will also prevent splinters.
6. Test the Push Block: Before using the push block, test it on a scrap piece of wood. Make sure it slides smoothly and gives you good control.

Detailed Steps with Images

Step	Description	Image
1. Cut Base	Cut plywood or hardwood to 6″ x 12″. This is the base.	Image of cutting a piece of wood with a table saw
2. Handle	Cut scrap wood to 2″ x 5″ for the handle. Shape the handle.	Image of shaping a handle with sandpaper
3. Attach	Glue and screw the handle to the base.	Image of attaching the handle to the base with screws
4. Non-Slip	Attach rubber or sandpaper to the bottom.	Image of attaching non-slip material to the base
5. Sand	Sand all edges for comfort.	Image of sanding the edges of the push block
6. Test	Test on scrap wood before use.	Image of testing the push block on a piece of wood

Advanced Push Block Techniques

Once you’re comfortable with a basic push block, you can try some advanced techniques. These can help you with more complex cuts.

Heel Push Block for Added Safety

A heel push block has a small heel that hooks over the back edge of the wood. This helps prevent kickback. It’s especially useful for ripping thin strips of wood.

1. Add a Heel: Attach a small piece of wood to the back of the push block. This piece should extend about 1/2 inch below the base.
2. Test the Heel: Make sure the heel catches the edge of the wood. This will help prevent the wood from lifting up during the cut.

Adjustable Push Block for Versatility

An adjustable push block can be adjusted to fit different thicknesses of wood. This makes it more versatile.

1. Use a Sliding Mechanism: Create a sliding mechanism with two pieces of wood. One piece slides inside the other.
2. Secure with a Knob: Use a knob to tighten the sliding mechanism. This will hold the push block at the desired height.

Choosing the Best Push Block Material

The best push block material is strong, durable, and easy to work with. Here are some good choices:

• Hardwood: Hardwood is strong and durable. It can withstand a lot of use.
• Plywood: Plywood is less expensive than hardwood. It’s also easy to work with.
• MDF: MDF is smooth and consistent. However, it’s not as strong as hardwood or plywood.

Comparing Material Options

Material	Pros	Cons	Best For
Hardwood	Strong, Durable, Long-lasting	More Expensive, Harder to Work With	Heavy Use, Professional Woodworkers
Plywood	Affordable, Easy to Work With	Less Durable Than Hardwood	General Use, DIY Projects
MDF	Smooth, Consistent, Easy to Finish	Not as Strong, Can Swell with Moisture	Light Use, Projects That Require a Smooth Finish

Safe Ripping on Table Saw: Tips and Tricks

Using a push block is just one part of safe ripping. Here are some other tips to keep in mind:

• Always Wear Safety Glasses: Safety glasses protect your eyes from flying debris.
• Use a Riving Knife or Splitter: A riving knife or splitter prevents the wood from pinching the blade.
• Stand to the Side: Stand to the side of the blade. This will protect you if kickback occurs.
• Keep Your Work Area Clear: A clear work area reduces the risk of accidents.
• Never Reach Over the Blade: Always use a push stick or push block to guide the wood.
• Feed the Wood Slowly and Steadily: Don’t force the wood through the blade. Let the blade do the work.
• Use Featherboards: Featherboards hold the wood against the fence. This helps prevent kickback and improves accuracy.
• Check the Wood for Knots: Knots can cause the wood to bind or kick back. Avoid cutting wood with large knots.

Creating an Ergonomic Push Block

An ergonomic push block is designed to be comfortable to use. This reduces fatigue and improves control. Here’s how to create an ergonomic push block:

• Shape the Handle: Shape the handle to fit your hand comfortably. Round the edges and make sure the grip is secure.
• Use a Comfortable Material: Use a material that is easy to grip. Rubber or foam can provide a comfortable grip.
• Adjust the Height: Adjust the height of the handle to fit your hand. This will reduce strain on your wrist and hand.
• Consider the Angle: Angle the handle slightly. This can make it easier to push the wood through the blade.

Maintaining Your Push Block

A well-maintained push block will last longer and work better. Here are some tips for maintaining your push block:

• Clean the Base: Clean the base regularly to remove dust and debris. This will help maintain the grip.
• Replace the Non-Slip Material: Replace the non-slip material when it wears out. This will ensure a good grip.
• Check the Screws: Check the screws regularly to make sure they are tight. Loose screws can make the push block unstable.
• Store Properly: Store the push block in a dry place. This will prevent it from warping or rotting.

Frequently Asked Questions (FAQ)

• What is the best material for a push block?

  The best material is typically hardwood or plywood. Hardwood is durable, while plywood is affordable and easy to work with.
  * Can I use a push stick instead of a push block?
  

  A push stick is useful for pushing the end of the wood. A push block is better for maintaining downward pressure and control. Using both can improve safe ripping on a table saw.
  * How do I prevent kickback when using a table saw?
  

  Use a push block, riving knife or splitter, and featherboards. Stand to the side of the blade and feed the wood slowly and steadily.
  * What is an ergonomic push block?

  An ergonomic push block is designed to be comfortable to use. It has a shaped handle, comfortable material, and adjustable height.
  * How often should I replace the non-slip material on my push block?

  Replace the non-slip material when it wears out or loses its grip. This will depend on how often you use the push block.

By following these instructions, you can make a safe and effective push block for your table saw. Remember to always prioritize safety when working with power tools. Happy woodworking!