What is a table saw push block and why do you need one? A table saw push block is a crucial safety tool for woodworkers. It helps you safely guide wood through your table saw, keeping your fingers away from the spinning blade. This guide will show you how to make your own effective wood push block with simple materials and tools. We’ll cover everything from basic push block design to advanced features, making it one of the most useful table saw accessories you can create.
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Why Make Your Own Push Block?
Buying pre-made push blocks is an option, but crafting your own offers several advantages. You can customize the size and features to perfectly suit your woodworking style and the types of cuts you typically make. Plus, it’s a cost-effective way to add essential safety equipment to your workshop. This DIY push stick project is rewarding and enhances your table saw safety stick capabilities significantly.
Essential Materials for Your Push Block
To build a solid and reliable push block, you’ll need a few basic items:
- Wood: A piece of hardwood, like maple, oak, or cherry, about 1 inch thick, 3-4 inches wide, and 6-8 inches long. This will form the main body of your push block.
- Handle Material: Another piece of wood, ideally a dowel rod or a shaped piece of hardwood, for the handle.
- Screws: Wood screws, typically 1 to 1.5 inches long, suitable for joining the handle to the body.
- Non-Slip Material (Optional but Recommended): A strip of rubber, cork, or even textured shelf liner to add grip to the bottom of the push block.
- Wood Glue: For added strength in joining parts.
Tools You’ll Need
Even without a full woodworking shop, you can make a great push block.
- Measuring Tape and Pencil: For accurate marking.
- Saw: A handsaw, miter saw, or table saw can be used to cut the wood.
- Drill and Drill Bits: For pre-drilling screw holes and creating pilot holes.
- Screwdriver: To drive the screws.
- Sandpaper: Various grits (e.g., 80, 120, 220) for smoothing edges and surfaces.
- Clamps (Optional): To hold pieces together while glue dries.
- Safety Glasses: Always wear these when working with tools.
Step-by-Step Guide: Building a Basic Push Block
This section details how to construct a simple yet effective wood push block.
Step 1: Preparing the Main Body
- Cut the Wood: Measure and cut your main piece of hardwood to your desired dimensions. A common size is around 6 inches long by 3 inches wide and 1 inch thick.
- Mark the Push Surface: On the bottom edge of the block, draw a line where you want the gripping surface to be. This is where the push block will contact the wood you are cutting. You can make this a straight line or a slightly angled one.
- Create the Grip: This is a key part of the push block design. For a basic push block, you can create a simple angled cut on the bottom edge. Set your table saw to a 5-10 degree bevel. Carefully pass the edge of the wood block over the blade to create a slight angle. This angled surface helps to grip the wood securely. If you don’t have a table saw, you can achieve a similar result with a rasp or sandpaper.
Step 2: Adding the Handle
- Shape the Handle: You can use a dowel rod, a piece of broomstick, or even a shaped piece of scrap wood for the handle. If using a dowel, cut it to a comfortable length, about 4-5 inches.
- Attach the Handle:
- Option A (Screws): Position the handle on the top of the push block where it feels comfortable to hold. Pre-drill pilot holes through the handle and into the main body of the push block. Then, drive wood screws to secure it.
- Option B (Glue and Dowel): Drill a hole into the top of the push block body and a corresponding hole into the handle. Apply wood glue to both surfaces and insert a dowel to connect them. Clamp them together until the glue dries.
- Reinforce with Screws (Optional): For extra strength, you can also add screws after the glue has dried.
Step 3: Adding Non-Slip Material (Optional but Recommended)
- Cut the Material: Cut a strip of rubber, cork, or textured liner to fit the bottom angled surface of your push block.
- Attach the Material: Apply wood glue or a strong adhesive to the angled surface. Press the non-slip material firmly onto it and wipe away any excess glue. You can also use small brad nails or staples to secure rubber strips.
- Trim Excess: Once the glue is dry, trim any excess material around the edges with a utility knife. This adds excellent grip and prevents the push block from slipping during use.
Step 4: Finishing Touches
- Sand Everything: Smooth all edges and surfaces with sandpaper. Start with a coarser grit (like 80 or 120) to remove any rough spots, then move to a finer grit (like 220) for a smooth finish. This makes the push block comfortable to hold and safe to use around your hands.
- Check for Sharp Edges: Ensure there are no splinters or sharp edges that could catch on your hands or the wood.
Advanced Push Block Designs and Features
Once you’ve mastered the basic wood push block, you can explore more advanced designs to enhance its functionality. This is where the concept of a woodworking jig truly comes into play.
1. The Keeper Push Block (for Tall Stock)
This design is excellent for pushing thinner pieces of wood through the saw when you need to keep them upright.
- Body: Start with a slightly larger block of wood, perhaps 1.5 inches thick.
- Vertical Guide: Cut a slot down the center of the block, going about halfway through its thickness. This slot should be wide enough to accommodate the height of the wood you’ll be cutting.
- Angled Base: Create the angled gripping surface on the bottom as described before.
- Handle: Add a comfortable handle.
When using this, the vertical slot guides your workpiece, and the angled base pushes it forward. This is a prime example of a useful table saw safety stick.
2. The “V” Groove Push Block
This design is particularly useful for cutting round stock like dowels or tenons.
- Body: Prepare your main block as usual.
- “V” Groove: On the bottom surface, cut a “V” shaped groove using a table saw with a dado blade or by making two angled cuts that meet in the middle. The angle of the “V” should be tight enough to grip round stock securely.
3. The Push Block with a Tenon Jig Feature
This advanced design combines a push block with a simple tenon jig.
- Body: A slightly larger block is needed.
- Angled Slot: Cut an angled slot (around 15-20 degrees) into the bottom edge of the block. This slot will hold your workpiece when making tenons.
- Clamp: You might add a small clamp or screw to help secure the workpiece in the angled slot.
This type of jig significantly expands the versatility of your push block.
4. The Push Block with a Zero Clearance Insert
This is a more advanced modification and often requires a dedicated jig to create.
- Concept: A small, thin piece of material (like a very thin laminate or hard plastic) is attached to the underside of the push block, creating a very tight fit against the table saw blade. This can help support thin materials and prevent tear-out.
- Execution: This usually involves precise routing or cutting to create a recessed area in the push block where the zero-clearance insert can be glued or screwed. It’s a more complex build but offers superior results for certain cuts. This is akin to a zero clearance insert for your table saw, but miniaturized for the push block.
Incorporating Table Saw Dust Collection
While not directly part of the push block itself, think about how your push block use interacts with table saw dust collection. A cleaner workspace is a safer workspace. Ensure your dust collection system is functioning well. When making your push block, consider its size and shape to avoid interfering with dust collection ports or shrouds. Some advanced push blocks can even incorporate small dust collection features if you’re building a more elaborate woodworking jig.
Safety First: Using Your Push Block Correctly
- Always use a push block or push stick for any cut where your fingers would come within 6 inches of the blade.
- Maintain contact with the wood and the push block throughout the entire cut.
- Never use a damaged or broken push block.
- Keep your push block clean and free of sawdust for optimal grip.
- Ensure the angled surface of your push block is in good condition.
Common Issues and Troubleshooting
- Slipping: If your push block slips, the non-slip material might be worn out, or the angled grip surface needs to be re-created or improved.
- Not Enough Grip: Re-apply non-slip material or consider a more aggressive texture. Ensure the angle on the bottom is steep enough for your needs.
- Uncomfortable Handle: Adjust the handle’s position or shape. If it feels awkward, you might need to rebuild the handle.
Frequently Asked Questions (FAQ)
Q: Can I use particleboard or MDF for a push block?
A: While possible, it’s not ideal. Hardwood is preferred because it’s denser, more durable, and less prone to splintering. Particleboard and MDF can break down easily with repeated use.
Q: What is the best angle for the grip on the bottom of the push block?
A: A 5-10 degree angle is a good starting point. For better grip on slicker woods, you might go slightly steeper. Experiment to see what works best for you.
Q: How close can my fingers be to the blade when using a push block?
A: The general rule of thumb is to keep your fingers at least 6 inches away from the blade. A push block allows you to achieve this safely.
Q: Do I need a special jig to make a push block?
A: For a basic wood push block, no. However, for more advanced features like “V” grooves or integrated tenon jig elements, a woodworking jig or specific table saw setups can make the process easier and more precise.
Q: How do I maintain my push block?
A: Keep it clean. Periodically check the non-slip material and the angled grip. If the grip wears down, you can re-cut it or apply new non-slip material. Sand any rough spots as needed.
Q: Can I make a push block that works for both rip cuts and crosscuts?
A: Yes, the basic design is versatile. For crosscuts, you might want a wider block. For rip cuts, a longer block can provide better control. Some woodworkers even have dedicated push blocks for different types of cuts.
Q: What’s the difference between a push block and a push stick?
A: A push stick is typically a simpler, thinner piece of wood used to push material. A push block is generally larger, often with a handle and a grippy surface, offering more control and safety, especially for thicker or wider pieces. Both are vital table saw accessories.
Conclusion
Creating your own table saw push block is a fundamental step towards safer and more efficient woodworking. By following this guide, you can craft a tool that not only protects your fingers but also improves the quality of your cuts. Remember that safety should always be your top priority, and a well-made push block is an indispensable part of any table saw operation. This DIY push stick project is a testament to the benefits of personalization in the workshop, turning a simple piece of wood into a vital table saw safety stick. Happy building and safe cutting!