How To Make a Table Saw Push Block: Safety First

Are you wondering how to make a table saw push block? A table saw push block is a critical safety device used to guide wood through the saw blade while keeping your hands safely away. This article will guide you through designing and crafting your own DIY push block, significantly enhancing your table saw safety and improving your woodworking accuracy.

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The Importance of a Table Saw Push Block

Why You Need a Push Block

Table saw safety should always be the priority in any woodworking shop. A push block is not just an accessory; it’s a necessity.

• Keeps Hands Safe: The primary function of a push block is to keep your hands away from the spinning blade. This is particularly crucial when cutting small or narrow pieces of wood.
• Improved Control: A good push block provides better control over the workpiece, ensuring consistent and accurate cuts. This leads to less waste and higher quality results.
• Prevents Kickback: By maintaining constant pressure and control, a push block helps prevent kickback, a dangerous situation where the wood is thrown back towards the operator.

Risks of Not Using a Push Block

Ignoring the use of a push block can lead to severe consequences.

• Serious Injury: The most obvious risk is injury to your hands and fingers. A momentary lapse in concentration can result in a painful and potentially life-altering accident.
• Damaged Workpiece: Without proper control, your cuts can be uneven or inaccurate, ruining your material and wasting your time.
• Increased Risk of Kickback: As mentioned earlier, kickback is a significant danger. It can damage your saw, injure you, and potentially cause damage to your workshop.

Types of Push Blocks

There are several types of push blocks available, each designed for specific tasks. Here’s a look at some common designs:

• Standard Push Block: A simple, rectangular block with a handle. Suitable for general use.
• Push Shoe: Features a heel or lip to grip the back edge of the workpiece. Ideal for thin or narrow stock.
• Long Push Stick: Provides extra reach, useful for pushing long pieces of wood through the saw.
• Specialty Push Blocks: Designed for specific cuts, such as mitered edges or dadoes.

Designing Your Own Push Block: Push Block Design

Creating your own shop-made push block allows you to tailor it to your specific needs and preferences. Here’s how to approach the design process.

Considerations for Push Block Design

• Ergonomics: The handle should be comfortable and provide a secure grip. Experiment with different shapes and angles to find what works best for you.
• Material: Choose a durable and stable material, such as hardwood or plywood. Avoid softwoods, which can wear down quickly.
• Size and Shape: The size of the push block should be appropriate for the type of work you typically do. Consider making multiple push blocks of different sizes.
• Grip: The base of the push block should provide a secure grip on the workpiece. This can be achieved through friction pads, rubber strips, or textured surfaces.

Essential Features of a Good Push Block

• Comfortable Handle: An ergonomic handle is crucial for maintaining control and reducing fatigue.
• Secure Grip: The base of the push block must have a non-slip surface to prevent it from sliding on the workpiece.
• Durable Construction: The push block should be made from sturdy materials that can withstand repeated use.
• Proper Size: The size of the push block should be appropriate for the size of the workpiece and the type of cut being made.
• Visibility: A bright color can help you see the push block clearly, even in a busy workshop.

Materials and Tools Needed

Before you start building your DIY push block, gather the necessary materials and tools.

Materials List

• Hardwood or Plywood: ¾” thick is a good starting point. Maple, birch, or Baltic birch plywood are excellent choices.
• Non-Slip Material: Rubber sheeting, adhesive-backed sandpaper, or textured paint.
• Screws or Glue: Wood screws or wood glue for assembling the push block.
• Finishing Material: Optional, but a coat of polyurethane can help protect the push block from moisture and wear.

Tools List

• Table Saw: For cutting the wood to size.
• Drill: For drilling pilot holes for screws.
• Screwdriver: For driving in the screws.
• Measuring Tape: For accurate measurements.
• Square: For ensuring right angles.
• Sandpaper: For smoothing the edges and surfaces.
• Clamps: For holding pieces together while the glue dries.

Step-by-Step Guide: Build Your Own Push Block

Here’s a detailed push block tutorial on how to make a simple yet effective standard push block.

Step 1: Cut the Base

• Measure and cut a piece of hardwood or plywood to the desired size for the base. A good starting point is 6″ wide by 8″ long.
• Ensure the edges are square and smooth.

Step 2: Cut the Handle

• Cut a piece of wood for the handle. A comfortable size is typically around 4″ wide by 6″ tall.
• Shape the handle for a comfortable grip. You can round the edges or create a more ergonomic shape.

Step 3: Attach the Handle

• Position the handle on top of the base, centered and aligned.
• Drill pilot holes through the base and into the handle.
• Secure the handle to the base with screws and glue.
• Clamp the pieces together until the glue dries.

Step 4: Add Non-Slip Material

• Cut a piece of non-slip material to fit the bottom of the base.
• Apply adhesive to the non-slip material or the base of the push block.
• Attach the non-slip material to the base, ensuring it is securely bonded.

Step 5: Sand and Finish

• Sand all the edges and surfaces of the push block to remove any sharp corners or splinters.
• Apply a finish, such as polyurethane, to protect the wood and enhance its durability.

Push Shoe Plans Example

Here’s a simple plan for creating a push shoe-style push block, perfect for handling thinner materials with added safety.

Part	Dimension (Inches)	Material	Quantity	Description
Base	4 x 8 x 3/4	Hardwood/Plywood	1	Main body that contacts the table surface
Handle	4 x 6 x 3/4	Hardwood/Plywood	1	Ergonomic grip
Heel	1 x 4 x 3/4	Hardwood/Plywood	1	Lip to catch the workpiece; essential for narrow pieces, prevents kickback
Non-Slip Pad	4 x 8	Rubber/Grip Material	1	Adhered to the base to provide a firm grip

Steps:

1. Prepare the Pieces: Cut the wood pieces according to the dimensions listed in the table. Ensure each piece is square.
2. Attach the Heel: Glue and screw the heel to one end of the base. The heel should extend below the base to catch the edge of the wood being cut.
3. Attach the Handle: Glue and screw the handle to the top of the base, positioning it for comfortable use.
4. Add Non-Slip Pad: Adhere the non-slip pad to the bottom of the base to prevent slipping during use.
5. Finishing Touches: Sand all edges and apply a finish to protect the wood.

This push shoe design offers enhanced control and safety when working with smaller or more delicate pieces on the table saw.

Safe Woodworking Techniques

General Safety Guidelines

• Read the Manual: Familiarize yourself with the table saw’s manual and safety guidelines before using it.
• Wear Safety Gear: Always wear safety glasses, hearing protection, and a dust mask when operating a table saw.
• Inspect the Saw: Before each use, inspect the saw for any damage or loose parts.
• Clear the Area: Keep the area around the table saw clear of obstructions and clutter.
• Use Proper Lighting: Ensure the work area is well-lit to improve visibility.
• Never Reach Over the Blade: Avoid reaching over the blade to retrieve a workpiece.
• Turn Off the Saw: Always turn off the saw and wait for the blade to stop spinning before making any adjustments.

Using a Push Block Safely

• Choose the Right Push Block: Select a push block that is appropriate for the size and shape of the workpiece.
• Maintain a Firm Grip: Hold the push block firmly and apply consistent pressure to the workpiece.
• Keep Your Hands Away from the Blade: Always keep your hands and fingers away from the blade.
• Use a Push Stick for Narrow Cuts: When cutting narrow pieces, use a push stick in conjunction with the push block for added safety.
• Never Force the Wood: If the wood is difficult to push through the saw, stop and check the blade alignment and fence position.
• Don’t Overreach: Make sure that you are not overreaching. If so, stop and adjust your stance.

Maintenance and Storage

Caring for Your Push Block

• Regular Cleaning: Clean your push block regularly to remove sawdust and debris.
• Inspect for Damage: Check for any cracks, chips, or loose parts. Replace the push block if it is damaged.
• Replace Non-Slip Material: Replace the non-slip material when it becomes worn or loses its grip.

Proper Storage

• Hang It Up: Store your push block in a convenient location where it is easily accessible.
• Keep It Clean: Store it in a clean, dry place to prevent damage and deterioration.

Enhancing Your Push Block

Adding Features for Specific Tasks

• Adjustable Heel: Design a push block with an adjustable heel to accommodate different thicknesses of wood.
• Dust Collection Port: Incorporate a dust collection port into the push block to help keep your work area clean.
• Integrated Featherboard: Combine a push block with a featherboard for added control and accuracy.

Experimenting with Different Designs

• Custom Handles: Try different handle shapes and sizes to find what feels most comfortable in your hand.
• Material Combinations: Experiment with different materials, such as combining wood with rubber or plastic, to create a unique push block.

Alternative Table Saw Accessories

While a push block is essential, consider these additional table saw accessories to further enhance your safety and workflow:

• Featherboards: These hold the workpiece firmly against the fence, preventing kickback and improving cut accuracy.
• Riving Knife: A riving knife sits behind the blade, preventing the wood from pinching and causing kickback.
• Blade Guard: A clear plastic guard that covers the blade, preventing accidental contact.
• Outfeed Table: Provides support for long pieces of wood as they exit the saw.
• Miter Gauge: Used for making accurate crosscuts and angled cuts.

Where to Find Push Block Plans and Inspiration

• Online Forums: Woodworking forums are a great source of ideas and inspiration.
• Woodworking Magazines: Many woodworking magazines feature articles on push block design and construction.
• YouTube: Watch videos of other woodworkers building push blocks to learn new techniques and tips.
• Pinterest: Search for “DIY push block” or “table saw accessories” on Pinterest for a visual feast of ideas.

FAQs: Safe Woodworking Techniques

• What is a push block used for?
  A push block is used to safely guide wood through a table saw blade, keeping your hands away from the cutting area and maintaining control over the workpiece.
  
• Can I use a push stick instead of a push block?
  Yes, a push stick can be used, especially for narrow cuts. However, a push block provides more stability and control for general use. It is beneficial to have both woodworking push stick types in your workshop.
  
• Who is the push block for?
  The push block is for anyone using a table saw. Regardless of skill level, it is an important tool for shop safety.
• What are the best materials for building a push block?
  Hardwood or plywood are the best materials. They are durable and provide a stable base.
• How often should I replace my push block?
  Replace your push block when it becomes damaged, worn, or loses its grip.
• What if I don’t have a workshop, can I still build a push block?
  Yes, as long as you can source wood and borrow or rent basic tools like a saw, drill, and screwdriver, you can construct a simple push block.

By following these guidelines, you can significantly enhance your table saw safety and improve the quality of your woodworking projects. Always prioritize safety, and remember that a well-made push block is an essential tool for any woodworker.