How To Make A Table Saw Push Stick: Improve Safety Now!

What is a table saw push stick? A table saw push stick is a simple but vital safety tool used to guide wood through the blade while keeping your hands safely away. It’s crucial for any woodworking shop using a table saw.

Table saws are powerful tools, but they can also be dangerous. One of the best ways to improve your table saw safety is by using a push stick. This article explains how to create your own DIY push stick and improve your woodworking safety. We’ll explore various woodworking push stick design options, the best push stick materials, and provide an easy push stick build with helpful DIY push stick plans.

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Why Use a Push Stick?

Using a push stick is essential for several reasons:

• Keeps Hands Away From the Blade: The primary function is to maintain a safe distance between your hands and the spinning blade.
• Provides Control: A good push stick offers better control over the workpiece, reducing the risk of kickback.
• Increases Accuracy: Consistent pressure and guidance contribute to more precise cuts.
• Reduces Fatigue: By providing a stable grip, push sticks lessen strain on your hands and arms.

Benefits of a Homemade Push Stick

While you can buy push sticks, making your own has distinct advantages:

• Customization: You can tailor the ergonomic push stick design to your hand size and preferred grip.
• Cost-Effective: Scrap wood can be used, saving money on table saw accessories.
• Immediate Availability: You can create one quickly if needed, without waiting for shipping.
• Learning Opportunity: The process enhances your woodworking skills.

Types of Push Sticks

There are various types of push sticks, each designed for specific tasks. Here are a few common styles:

• Standard Push Stick: A basic, flat stick with a notched end to grip the wood. Ideal for general use.
• Paddle Push Stick: Features a wider “paddle” for pushing wider boards.
• Long Push Stick: Used for pushing long boards through the saw, offering extended reach.
• Heel Push Stick: Incorporates a “heel” to grip the trailing edge of the wood. This is a great push block alternative.

Materials for Your Push Stick

Choosing the right materials is vital for creating a durable and effective push stick. Here are some excellent options:

• Hardwood: Maple, oak, and birch are strong and resistant to wear.
• Plywood: Baltic birch plywood is a stable and robust choice.
• Solid Wood Alternatives: MDF or other composite boards can work if sealed well.

Table: Material Comparison

Material	Pros	Cons
Hardwood	Durable, wear-resistant, comfortable grip	Can be more expensive, may require more complex shaping
Baltic Birch Plywood	Stable, strong, readily available, less prone to warping	Edges may require sealing, can be less aesthetically pleasing
MDF	Inexpensive, easy to shape	Less durable, susceptible to moisture damage

Designing Your Push Stick: DIY Push Stick Plans

Before you start building, consider these design elements for an ergonomic push stick:

• Handle: Should be comfortable to grip and large enough to accommodate your hand.
• Body: The main section that provides support and guidance.
• Notch/Heel: The gripping part that contacts the wood.
• Angle: Slight angles in the design can improve grip and control.

Here are a couple of basic DIY push stick plans you can adapt:

Plan 1: Simple Push Stick

This is an easy push stick build, perfect for beginners.

1. Cut a piece of wood approximately 12″ long, 3″ wide, and 3/4″ thick.
2. Shape the handle by rounding the top edge for a comfortable grip.
3. Cut a notch about 1″ deep and 1″ wide at one end to grip the wood.
4. Sand all edges smooth to prevent splinters.

Plan 2: Heel Push Stick

This design is useful for finishing cuts and preventing kickback.

1. Cut a piece of wood approximately 12″ long, 4″ wide, and 3/4″ thick.
2. Shape the handle as desired.
3. Cut a notch at one end similar to the simple push stick.
4. Add a “heel” by attaching a small piece of wood (about 2″ x 2″) to the bottom edge, behind the notch. This heel will grip the trailing edge of the workpiece.
5. Sand all edges smooth.

Push Stick Template

Consider creating a push stick template from cardboard or thin plywood. This will help you consistently reproduce the design and ensure accurate cuts. You can find free templates online or design your own.

Step-by-Step: Homemade Push Stick Tutorial

Follow this homemade push stick tutorial to build your own table saw safety tool:

Step 1: Gather Your Materials and Tools

• Chosen wood (hardwood, plywood, etc.)
• Saw (table saw, bandsaw, or jigsaw)
• Measuring tape or ruler
• Pencil
• Sandpaper (various grits)
• Wood glue (if adding a heel or other attachments)
• Clamps (if gluing)
• Safety glasses
• Hearing protection

Step 2: Cut the Wood to Size

Using your chosen plan or template, measure and cut the wood to the required dimensions. Ensure the cuts are straight and accurate.

Step 3: Shape the Handle

Shape the handle for a comfortable grip. You can round the edges with sandpaper, a router, or a spokeshave.

Step 4: Create the Notch or Heel

Cut the notch or attach the heel according to your chosen design. A table saw or bandsaw works well for this, but a jigsaw can also be used.

Step 5: Sand All Surfaces

Sand all edges and surfaces smooth to remove any sharp edges or splinters. Start with a coarser grit sandpaper (e.g., 80-grit) and gradually move to finer grits (e.g., 220-grit) for a smooth finish.

Step 6: Apply Finish (Optional)

Applying a finish, such as varnish or polyurethane, can improve the push stick’s durability and water resistance. This is particularly recommended if you’re using MDF or a similar composite material.

Step 7: Inspect and Test

Before using the push stick, carefully inspect it for any flaws or weaknesses. Test it on a scrap piece of wood to ensure it provides a secure grip and comfortable control.

Advanced Push Stick Design Ideas

Once you’re comfortable with the basic designs, you can explore more advanced features:

• Interchangeable Grips: Design the push stick with a system to swap out different types of grips for various tasks.
• Adjustable Height: Create a push stick with an adjustable height to accommodate different wood thicknesses.
• Built-in Dust Collection: Incorporate a dust collection port to help keep your workspace clean.
• Ergonomic Handle Options: Experiment with different handle shapes and materials to find the most comfortable option for your hand.

Maintaining Your Push Stick

Proper maintenance will extend the life of your push stick and ensure its continued effectiveness:

• Regular Inspection: Check for cracks, chips, or other damage before each use.
• Cleaning: Remove sawdust and debris regularly with a brush or compressed air.
• Sanding: Re-sand any rough edges or splinters as needed.
• Replacement: If the push stick becomes severely damaged or worn, replace it immediately.

Where Can I Find More Information About Table Saw Safety Tools?

You can find lots of information about table saw safety tools on woodworking forums, YouTube channels dedicated to woodworking, manufacturer websites for table saws and accessories, and articles published by woodworking safety organizations.

Can I Use a Push Stick with Other Power Tools?

While push sticks are primarily designed for table saws, similar tools can be adapted for use with jointers and routers to maintain safe distances between your hands and the cutting blades or bits.

Table Saw Safety Tips

In addition to using a push stick, follow these general table saw safety tips:

• Wear safety glasses and hearing protection.
• Ensure the blade is sharp and properly aligned.
• Use a splitter or riving knife to prevent kickback.
• Stand to the side of the blade during cuts.
• Never reach over the blade while it is running.
• Keep your work area clean and well-lit.
• Disconnect the power before making adjustments or changing blades.
• If you’re feeling tired or distracted, stop working.
• Never force the wood through the saw. Let the blade do the work.
• Read and understand the table saw’s manual before use.

Conclusion

Making your own table saw push stick is a simple yet crucial step in improving your woodworking safety. By following these DIY push stick plans and tips, you can create a custom woodworking push stick design that fits your needs and preferences. Remember to prioritize safety in your workshop and always use table saw safety tools like a push stick to protect yourself from injury. With a little effort, you can enjoy woodworking safely and confidently. The goal is to get started on an easy push stick build today!

Frequently Asked Questions (FAQ)

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

A: Hardwoods like maple, oak, or birch are excellent choices due to their durability and resistance to wear. Baltic birch plywood is also a good option.

Q: How often should I replace my push stick?

A: Replace your push stick immediately if it becomes damaged, worn, or compromised in any way. Regular inspection will help you identify when a replacement is needed.

Q: Can I use a push block instead of a push stick?

A: Yes, a push block can be a good push block alternative, especially for wider boards or more complex cuts. Push blocks offer a larger surface area for better control and can provide additional protection for your hands.

Q: Where can I find a push stick template?

A: Many woodworking websites and forums offer free push stick template downloads. You can also create your own template based on your desired design.

Q: What if I don’t have a table saw to make a push stick?

A: You can use a bandsaw, jigsaw, or even hand tools to cut and shape the push stick. The key is to ensure the cuts are accurate and the edges are smooth.

Q: Is it safe to use a push stick with a dull blade?

A: No. Using a dull blade with any push stick can increase the risk of kickback and injury. Ensure your blade is sharp and properly maintained for safe operation.

Q: How can I customize my push stick for a better grip?

A: You can customize your ergonomic push stick with different handle shapes, materials (like rubber or foam), or even add finger grooves for a more secure grip. Experiment to find what works best for you.