How To Make a Push Stick for a Table Saw: Safety First!

Are you wondering how to make a push stick for a table saw? A push stick is a simple but crucial tool for table saw safety. It helps you guide wood through the blade while keeping your hands a safe distance away. This guide provides push stick plans and shows you how to make your own DIY push stick to improve table saw safety in your woodshop safety practices. It’s a great table saw accessory and a good push block alternative.

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The Critical Role of a Push Stick in Table Saw Operations

The table saw is a powerful and versatile tool, but it’s also one of the most dangerous in the woodshop. Table saw safety relies heavily on using the right techniques and tools. A woodworking push stick is essential for safely guiding your workpiece through the blade, preventing kickback and protecting your fingers.

Why Use a Push Stick?

• Keeps Hands Safe: The primary function is to keep your hands away from the blade.
• Prevents Kickback: By maintaining consistent pressure, it helps prevent the wood from being thrown back toward you.
• Improved Control: A push stick gives you better control over the workpiece, leading to cleaner and more accurate cuts.
• Essential for Thin Cuts: Crucial when cutting narrow pieces where your hands would be too close to the blade.

Types of Cuts Requiring a Push Stick

A push stick isn’t just for small pieces; it’s valuable in many situations.

• Ripping Narrow Boards: When ripping boards less than 6 inches wide.
• Cutting Small Parts: Cutting small parts that are difficult to hold.
• Dealing with Warped Wood: When dealing with wood that may bind or pinch the blade.
• Final Cuts: For pushing the last bit of material past the blade for a complete cut.

Designing Your DIY Push Stick: Push Stick Plans

There are many push stick plans available, each with its own advantages. Here, we’ll look at a few common designs and offer a detailed guide to building a simple but effective model.

Types of Push Stick Designs

Type	Description	Advantages	Disadvantages
Straight Push Stick	A flat piece of wood with a handle.	Simple to make, good for general use.	Less effective for thin pieces or when more control is needed.
L-Shaped Push Stick	Shaped like an “L” with a handle and a fence-riding edge.	Offers good control, can ride along the fence.	Can be bulky, requires more material.
Gripping Push Stick	Features a non-slip material on the bottom to grip the wood.	Enhances grip, prevents slipping.	Requires additional materials (non-slip pads).
Long Handle Push Stick	Has a longer handle for increased reach.	Keeps hands further from the blade, ideal for larger projects.	Can be unwieldy for smaller cuts.

Simple and Effective Push Stick Plan

This design combines simplicity with functionality, making it ideal for beginners.

Materials:

• Scrap piece of plywood or hardwood (approximately ¾” thick, 6″ wide, and 12″ long)
• Wood glue
• Screws (optional)
• Sandpaper (120 grit and 220 grit)

Tools:

• Table saw (ironically!)
• Measuring tape
• Pencil
• Drill (optional, for screws)
• Clamps

Step-by-Step Instructions:

1. Prepare the Wood: Cut your piece of wood to the dimensions mentioned above (¾” x 6″ x 12″). Make sure the edges are straight and smooth.

2. Mark the Handle: On one end of the board, mark a line 2″ from the edge. This will be the bottom of your handle.

3. Cut the Handle: Use your table saw (or a bandsaw if you have one) to cut away the excess wood above the line, creating a handle. Round the top corners of the handle for comfort.

4. Create the Notched Heel: On the opposite end of the handle (the “pushing” end), make a notch. This notch will grip the end of the wood as you push it through the blade.

   • Mark a line 1″ deep and 2″ wide centered on the end of the board.
   • Carefully make two parallel cuts into the end of the board along the 1″ deep lines.
   • Use a chisel or your table saw (with extreme caution) to remove the wood between the cuts, creating the notch.

5. Reinforce (Optional): For added strength, glue and screw a small piece of wood (approximately ¾” x 2″ x 4″) behind the notch to reinforce it. This will prevent the notch from breaking under pressure.

6. Sand the Push Stick: Sand all edges and surfaces smooth using 120-grit sandpaper, followed by 220-grit sandpaper. This will eliminate splinters and make the push stick more comfortable to use.

7. Finish (Optional): Apply a coat of finish (such as polyurethane or varnish) to protect the wood and make it more durable.

Alternative Design: The L-Shaped Push Stick

The L-shaped push stick is another popular choice. Here’s how to make one:

Materials:

• Two pieces of ¾” plywood or hardwood: one 6″ x 12″, the other 4″ x 12″
• Wood glue
• Screws
• Sandpaper

Instructions:

1. Prepare the Pieces: Cut your wood pieces to size.
2. Assemble the L: Glue and screw the smaller piece of wood to the edge of the larger piece, forming an “L” shape. Ensure the pieces are square.
3. Shape the Handle: Round the top corners of the vertical piece for a comfortable grip.
4. Add a Notch: Cut a small notch at the bottom edge of the vertical piece to grip the workpiece.
5. Sand and Finish: Sand all edges smooth and apply a finish.

Using Your Homemade Push Stick Effectively

Having a push stick is only half the battle; improving table saw safety also means knowing how to use it properly.

Correct Hand Placement

Always keep your hands behind the push stick and away from the blade’s path. Never reach over the blade.

Maintaining Consistent Pressure

Apply even pressure to the push stick as you guide the wood through the blade. Avoid jerky movements, which can cause kickback.

Fence Alignment

Keep the push stick pressed firmly against the fence to ensure a straight and accurate cut.

Avoiding Overreach

Use a second push stick or push block if you need to push the workpiece completely past the blade, especially for longer pieces.

Replace When Worn

Check your push sticks regularly and replace them when they become worn, damaged, or splintered. A damaged push stick is less effective and can be a safety hazard.

Enhancing Your Table Saw Safety Setup

A push stick is a valuable tool, but it’s only one component of a comprehensive safety strategy.

Additional Safety Equipment

• Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.
• Hearing Protection: Table saws can be very loud; wear earplugs or earmuffs to protect your hearing.
• Dust Mask or Respirator: Sawing wood creates dust; wear a dust mask or respirator to protect your lungs.
• Featherboards: These provide consistent pressure against the fence and table, further reducing the risk of kickback.
• Riving Knife or Splitter: These devices help prevent the wood from pinching the blade and causing kickback.
• Push Blocks: Offer a larger surface area for pushing material, sometimes preferred over push sticks for certain tasks.

Best Practices for Table Saw Operation

• Inspect the Saw: Before each use, inspect the saw for any damage or loose parts.
• Use Sharp Blades: Dull blades are more likely to cause kickback.
• Adjust Blade Height: Set the blade height so that the teeth extend just above the workpiece.
• Stand to the Side: Avoid standing directly behind the blade’s path in case of kickback.
• Never Reach Over the Blade: Always turn off the saw before reaching over the blade to retrieve a piece of wood.
• Use Outfeed Support: Use rollers or tables to support long pieces of wood as they exit the saw.
• Avoid Freehand Cuts: Always use the fence or miter gauge to guide your cuts.
• Stay Focused: Avoid distractions and maintain your concentration while operating the saw.

Deciphering Common Table Saw Hazards

Knowing the risks is crucial for staying safe.

Kickback

Kickback occurs when the wood is pinched between the blade and the fence, causing it to be thrown back toward the operator. This can happen when ripping wood, especially if the wood is warped or if the riving knife is not properly adjusted.

Blade Contact

Accidental contact with the blade is a major cause of injury. This can happen when reaching over the blade, losing control of the workpiece, or using the saw without proper safety equipment.

Flying Debris

Sawdust and wood chips can be thrown into the air at high speeds, posing a risk to your eyes and respiratory system.

Noise Exposure

Prolonged exposure to the loud noise of a table saw can cause hearing damage.

Fathoming the Benefits of Regular Maintenance

Regular maintenance is essential for keeping your table saw in good working order and ensuring your safety.

Blade Maintenance

• Sharpening: Keep your blades sharp for clean and efficient cuts.
• Cleaning: Clean your blades regularly to remove resin and pitch buildup.
• Inspection: Check your blades for damage or wear before each use.

Saw Alignment

• Fence Alignment: Ensure your fence is parallel to the blade.
• Miter Slot Alignment: Ensure your miter slot is parallel to the blade.
• Blade Alignment: Check that the blade is perpendicular to the table.

General Maintenance

• Lubrication: Lubricate moving parts to ensure smooth operation.
• Cleaning: Remove sawdust and debris from the saw.
• Inspection: Inspect the saw for loose parts or damage.
• Riving Knife/Splitter Adjustment: Regularly check and adjust the riving knife or splitter to ensure it’s properly aligned with the blade.

Woodworking Push Stick: Choosing the Right Material

The material you use for your push stick matters. Hardwoods like maple or oak are durable choices. Plywood is also an option but ensure it’s high-quality and void-free to prevent splintering. Avoid softwoods that can easily break down.

Homemade Push Stick: Personalization and Customization

Your push stick doesn’t have to be basic. Customize it to fit your needs. Add a comfortable handle, non-slip grips, or a unique shape. The key is to make it comfortable and effective for you.

Interpreting Push Block Alternative Options

While push sticks are great, push blocks offer an alternative. Push blocks have a larger surface area, providing more stability, especially for larger pieces. Some prefer them for their ergonomic design. Experiment to see which works best for you.

Grasping the Importance of Education and Training

No tool is safe without proper training. Take woodworking classes, watch instructional videos, and practice using your table saw and push stick safely. Continued education is key to preventing accidents.

Frequently Asked Questions (FAQ)

Q: What is the best material for a push stick?
A: Hardwoods like maple or oak are ideal due to their durability. High-quality plywood is also a good option.

Q: Can I use a push stick for all cuts on a table saw?
A: While highly recommended for narrow cuts and when your hands are close to the blade, a push stick isn’t always necessary for very wide boards. However, it’s a good habit to use it whenever possible for added safety.

Q: Who is responsible for ensuring table saw safety in a workshop?
A: Everyone in the workshop is responsible for safety. Employers must provide a safe environment and training, while individual users must follow safety procedures.

Q: What should I do if my push stick breaks during a cut?
A: Immediately turn off the saw and assess the situation. Do not attempt to retrieve the broken piece until the blade has completely stopped. Replace the push stick before resuming work.

Q: How often should I replace my push stick?
A: Replace your push stick whenever it becomes worn, damaged, or splintered. Regular inspection is crucial.

Q: What are some signs that I need a new push stick?
A: Look for cracks, splinters, excessive wear on the pushing edge, or a loose handle.

By following these guidelines and prioritizing table saw safety, you can confidently and safely use your table saw for years to come. Remember, a little preparation and caution go a long way in woodshop safety. Creating your own DIY push stick is a small investment that can significantly improve your table saw safety and overall woodworking experience.