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

What is a push stick for a table saw? A push stick is a vital safety tool used to guide wood through a table saw blade, keeping your hands away from the spinning blade. This blog post will guide you through making your own DIY table saw push stick, ensuring safe table saw operation while tackling your woodworking project safety.

Image Source: i0.wp.com

The Indispensable Push Stick: Your Hand’s Best Friend

The table saw is a powerhouse in any woodworking shop, but its power demands respect. Safe table saw operation hinges on several factors, and one of the most crucial is using a push stick. It’s not just an table saw accessory; it’s a barrier between your fingers and a potentially devastating accident. Ignoring this small piece of wood can have serious consequences. This article will show you how to make a reliable shop-made push stick that you can rely on.

Why You Absolutely Need a Push Stick

Think of the push stick as an extension of your hand. It provides a safe and controlled way to advance wood across the blade, especially when cutting narrow pieces. Here’s why it’s so important:

• Keeps Hands Away from the Blade: This is the most obvious and most critical benefit.
• Maintains Control: A good push stick offers a firm grip, preventing the wood from kicking back or wandering off course.
• Prevents Injury: Table saw accidents can lead to serious injuries. A push stick drastically reduces the risk.
• Improves Accuracy: With a secure grip, you can make more precise cuts.

Designing Your Perfect Push Stick: Considerations for Safety and Function

Push stick design is not a one-size-fits-all affair. The best design for you depends on the type of cuts you frequently make and your personal preferences. Let’s look at some essential elements.

Ergonomics: Comfort is Key

A comfortable push stick is a safe push stick. If it’s awkward or difficult to hold, you’re more likely to make mistakes. Consider these ergonomic factors:

• Handle Shape: A comfortable handle is easy to grip. Experiment with different shapes (e.g., rounded, angled) to find what feels best.
• Handle Size: The handle should be large enough to accommodate your hand comfortably, even while wearing gloves.
• Grip Material: Adding a rubber or non-slip grip can improve control, especially when working with damp or oily wood.

Types of Push Stick Designs: Choosing the Right Style

There are several common push stick designs, each with its strengths and weaknesses. Here’s a rundown of some popular choices:

Type	Description	Pros	Cons
Standard Push Stick	A simple stick with a notch or hook at the end to grip the workpiece.	Easy to make, good for general-purpose use.	May not be ideal for very thin or narrow pieces.
L-Shaped Push Stick	Features an “L” shape, providing both downward and forward pressure.	Offers excellent control, suitable for a wide range of cuts.	Can be slightly more difficult to maneuver around the blade.
Push Block	A larger, more substantial tool with a handle on top and a non-slip base.	Provides maximum control and safety, especially for larger pieces.	Can be more expensive and take up more storage space.
Heel Push Stick	Has a heel that fits over the back of the workpiece to ensure a secure grip.	Great for safely finishing cuts when the workpiece is nearing the end of the blade.	Not as versatile as other designs for general-purpose use.

Key Features for All Push Sticks

Regardless of the specific design, every push stick should have these essential features:

• Durable Material: Choose a hardwood like maple, oak, or birch. Avoid softwoods like pine, which can splinter easily.
• Sufficient Length: The push stick should be long enough to keep your hand a safe distance from the blade throughout the cut.
• Secure Grip: The notch, hook, or handle must provide a solid grip on the workpiece.
• Smooth Bottom: The bottom of the push stick should be smooth to glide easily across the table saw surface.
• Bright Color: Paint your push stick a bright color (e.g., orange, yellow) to make it highly visible and less likely to get lost in your shop.

Making Your Own Push Stick: A Step-by-Step Guide

Now, let’s get to the practical part: making push stick jigs. This guide will walk you through creating a simple yet effective L-shaped push stick.

Materials and Tools You’ll Need

• Hardwood (maple, oak, or birch) – approximately 3/4″ thick, 4″ wide, and 12″ long
• Pencil and ruler
• Table saw (obviously!)
• Band saw or jig saw (optional, but helpful for curved cuts)
• Drill with various sized bits
• Wood glue
• Screws (optional, for extra reinforcement)
• Sandpaper (various grits)
• Paint or finish (optional)

Step-by-Step Instructions

1. Prepare the Wood: Cut the hardwood to the desired dimensions. A piece that’s about 3/4″ thick, 4″ wide, and 12″ long is a good starting point. Ensure the edges are straight and square.
2. Mark the Design: Using a pencil and ruler, draw the outline of your L-shaped push stick on the wood. The “foot” of the “L” (the part that will push the wood) should be about 2-3″ long. The handle portion should extend far enough to keep your hand well away from the blade (at least 6-8″).
3. Cut Out the Shape: Carefully cut out the shape using your table saw. For the inside corner of the “L”, you can use a band saw or jig saw to make a curved cut. Alternatively, you can drill a hole at the corner and then use the table saw to make straight cuts up to the hole.
4. Create the Notch or Hook: This is the most important part. The notch or hook will grip the workpiece. There are a couple of ways to do this:
   • Notch: Cut a notch into the foot of the push stick, about 1/2″ deep and 1/2″ wide. This is simple but effective.
   • Hook: Cut a longer, angled notch to create a hook. This provides a more secure grip, especially for thin pieces.
5. Sand the Edges: Use sandpaper to smooth all the edges and corners of the push stick. This is important for comfort and safety. Remove any splinters or sharp edges.
6. Add a Handle (Optional): You can add a separate handle to the top of the push stick for a more comfortable grip. Cut a small piece of wood and shape it to fit your hand. Attach it to the push stick with wood glue and screws.
7. Apply Finish (Optional): You can apply a coat of paint or finish to protect the wood and make the push stick more durable. A bright color is recommended for visibility.
8. Test and Adjust: Before using your new push stick, test it on a scrap piece of wood. Make sure it provides a secure grip and that you can comfortably control the workpiece. Adjust the design if necessary.

Making it Better: Customizing Your Push Stick

Once you’ve mastered the basic L-shaped push stick, you can start experimenting with different designs and features. Here are some ideas:

• Replaceable Feet: Design your push stick with replaceable feet. This allows you to easily replace worn or damaged feet without having to make a whole new push stick.
• Adjustable Height: Create a push stick with an adjustable height to accommodate different thicknesses of wood.
• Built-in Featherboard: Incorporate a small featherboard into your push stick to provide extra downward pressure and prevent the wood from lifting off the table.
• Storage: Build a dedicated storage rack or holder for your push sticks near your table saw to keep them readily accessible.

Alternative Push Stick Methods: When You Need a Different Approach

While the standard push stick is a workhorse, sometimes you need something different. Understanding push block alternatives is essential.

Using Push Blocks for Large Pieces

For larger, heavier pieces of wood, a push block is a better choice than a push stick. Push blocks are larger and provide more surface area for better control. They typically have a handle on top for a comfortable grip.

Featherboards: An Extra Layer of Safety

Featherboards are another woodworking safety tool that can be used in conjunction with a push stick. They provide consistent pressure against the fence, preventing the wood from wandering off course.

When Hand Pressure is Necessary (and How to Do it Safely)

There are some situations where using a push stick isn’t practical, such as when making very shallow cuts or when working with extremely thin pieces of wood. In these cases, you may need to use hand pressure. However, it’s critical to know table saw safety tips.

• Keep your hands flat: Never cup your hands over the workpiece.
• Use a featherboard: To keep the workpiece pressed against the fence.
• Make the cut in multiple passes: If possible, take several shallow cuts instead of one deep cut.
• Stay focused: Avoid distractions and concentrate on the cut.
• If in doubt, don’t: If you’re uncomfortable making the cut with hand pressure, find another method or skip the cut altogether.

Maintaining Your Push Stick: Keeping it in Tip-Top Shape

A well-maintained push stick is a safe push stick. Here are some tips for keeping yours in good condition:

• Inspect Regularly: Check your push stick before each use for cracks, splinters, or damage.
• Clean it Frequently: Wipe off any sawdust, resin, or oil.
• Replace Worn Parts: If the notch or hook becomes worn, replace it or make a new push stick.
• Store Properly: Store your push sticks in a dry, easily accessible location.

Common Mistakes to Avoid: Keeping Your Fingers Safe

Even with a good push stick, it’s possible to make mistakes. Here are some common errors to avoid:

• Reaching Over the Blade: Never reach over the spinning blade to retrieve a workpiece.
• Cutting Without a Fence: Always use a fence to guide the wood, unless you’re making a freehand cut (which should be avoided unless absolutely necessary).
• Forcing the Wood: If the wood is binding, stop and investigate the cause. Don’t force it through the blade.
• Using a Dull Blade: A dull blade requires more force, increasing the risk of kickback.
• Ignoring Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.

Fathoming Table Saw Safety: A Holistic Approach

Using a push stick is just one piece of the puzzle. Woodworking safety tools and practices require a complete plan. Here are some additional table saw safety tips to keep in mind:

• Read the Manual: Familiarize yourself with the specific safety instructions for your table saw.
• Wear Appropriate Clothing: Avoid loose clothing, jewelry, or long hair that could get caught in the blade.
• Use Hearing Protection: Table saws are loud. Protect your hearing with earplugs or earmuffs.
• Ensure Adequate Lighting: Good lighting is essential for seeing what you’re doing.
• Stay Sober: Never operate a table saw under the influence of alcohol or drugs.
• Keep Your Work Area Clean: A cluttered workspace is a dangerous workspace.

By following these tips and using a well-made push stick, you can significantly reduce the risk of injury and enjoy your woodworking projects safely.

Frequently Asked Questions (FAQ)

Q: Can I use a piece of scrap wood as a push stick?

A: While tempting, using just any scrap wood is not recommended. A properly designed and constructed push stick offers a much better grip and is far less likely to slip or break, increasing safety.

Q: How often should I replace my push stick?

A: Inspect your push stick regularly. Replace it immediately if you notice any cracks, excessive wear, or damage to the gripping surface.

Q: What is the best wood to use for a push stick?

A: Hardwoods like maple, oak, or birch are ideal. They are durable and less likely to splinter compared to softwoods like pine.

Q: Can I buy a push stick instead of making one?

A: Yes, you can purchase push sticks. However, making your own allows you to customize the design to fit your specific needs and preferences, and it can be more cost-effective.

Q: Is a push stick necessary for every cut?

A: While not every cut requires a push stick, it’s best to err on the side of caution. Always use a push stick when cutting narrow pieces, when your hands are close to the blade, or when you feel uncomfortable with the cut. It’s a cheap insurance to practice safe table saw operation.