Can I make a push block for my table saw? Yes, you absolutely can and should! Making your own table saw push block is a straightforward and highly beneficial woodworking project. It’s a crucial step in enhancing table saw safety and ensuring clean, accurate cuts. A well-made DIY push block or homemade table saw push block can elevate your woodworking experience significantly, acting as a vital safety push block table saw tool.
This guide will walk you through the process of building your own robust and effective table saw push block. We’ll cover everything from material selection to the final construction, ensuring you have the knowledge to create a woodworking push block that will serve you for years to come. Mastering the art of building a push block is a fundamental skill for any serious woodworker.
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Why You Need a Table Saw Push Block
The table saw, while an incredibly versatile tool, also presents significant safety risks. The spinning blade, powerful motor, and the need to guide wood through it all combine to create a situation where accidents can happen quickly. This is where a table saw push stick becomes indispensable.
A push block does more than just push wood; it keeps your hands a safe distance from the blade. It provides downward pressure to prevent the wood from lifting off the table or jumping over the blade. This downward force is critical for preventing kickback, a violent and dangerous phenomenon where the workpiece is thrown back towards the operator. Using a safety push block table saw is one of the most effective ways to mitigate this risk.
Beyond safety, a good push block offers control. It helps you maintain a consistent feed rate, leading to cleaner cuts and fewer mistakes. It can also help with precise alignment against the fence. Think of it as an extension of your hands, offering both protection and precision. A table saw push guide aspect is also important; it helps keep the wood moving straight.
Essential Table Saw Safety Tools
Before we dive into building, let’s briefly touch upon other essential table saw safety tools that complement your new push block:
- Push Sticks: While a push block is fantastic for many operations, traditional push sticks are still useful for very thin stock or for operations where you need to push wood completely past the blade. They are also great for cutting smaller pieces.
- Blade Guards: Most modern table saws come with a blade guard. Always ensure yours is properly installed and functioning.
- Riving Knife/Splitter: This is a metal plate positioned behind the blade. It prevents the kerf from closing up and pinching the blade, a common cause of kickback. It’s arguably the most important kickback prevention device.
- Anti-Kickback Pawls: These are small, toothed devices that, when properly engaged, dig into the wood if it starts to move backward, stopping kickback.
- Dust Collection: While not directly a safety tool in the kickback sense, good dust collection improves visibility and air quality, contributing to a safer working environment.
- Safety Glasses/Hearing Protection: Non-negotiable for any power tool operation.
Your DIY push block is a key part of this safety arsenal. It’s a table saw accessory that you can build with specific features tailored to your needs.
Designing Your DIY Push Block
When considering building a push block, design is paramount. A good design balances functionality, safety, and ease of use.
Key Design Features:
- Grip: The push block needs a comfortable and secure grip. This typically involves a handle or a raised section.
- Pushing Surface: The face of the block that contacts the wood needs to provide good friction. It should be flat and square to the sides.
- Hold-Down: The best push blocks incorporate a way to apply downward pressure. This is often achieved with a rubber or foam pad on the bottom.
- Size and Weight: It should be substantial enough to provide leverage but not so large that it’s cumbersome.
Common Push Block Styles:
- Simple Block: A basic rectangular block of wood with a comfortable grip.
- T-Handle Block: Features a T-shaped handle for a more ergonomic and secure hold.
- Angled Push Block: Designed with an angled pushing surface to help guide the workpiece against the fence.
- Push Block Jig: This can refer to a more complex jig that might hold the workpiece more securely or offer multiple functions. For this guide, we’ll focus on a robust, single-purpose push block.
Materials You’ll Need
For a durable and effective homemade table saw push block, selecting the right materials is crucial.
- Wood: Hardwoods like maple, oak, or cherry are excellent choices. They are dense, stable, and provide a good surface. Avoid softwoods like pine, as they can dent and wear down quickly. A piece of 2×4 (which is actually 1.5″ x 3.5″) is a common starting point.
- Grip Material:
- Rubber Sheet/Pad: A non-slip rubber mat or a piece of an old tire tube works well.
- Cork Sheet: Provides good friction and is easy to work with.
- Grippy Tape: Similar to what’s used on skateboard decks or sporting equipment.
- Fasteners:
- Wood Screws: For joining pieces of wood. Use screws that are long enough to securely join the components but not so long that they protrude.
- Double-Sided Tape (Heavy Duty): For attaching the grip material.
- Adhesives:
- Wood Glue: For strong wood-to-wood bonds.
- Contact Cement: For attaching rubber or cork.
Tools You’ll Need:
- Table Saw: Of course!
- Measuring Tape and Pencil: For accurate marking.
- Safety Glasses and Hearing Protection: Absolutely essential.
- Clamps: To hold pieces securely while gluing or drilling.
- Drill and Drill Bits: For pilot holes and countersinking.
- Screwdriver or Drill Driver: For driving screws.
- Saw Blade (for table saw): A combination or crosscut blade is ideal.
- Optional: Router with a roundover bit for comfortable edges, sandpaper for smoothing.
Step-by-Step Guide: Building a Classic T-Handle Push Block
This design is a popular and effective choice for a table saw push stick. It offers a good balance of control, safety, and comfort.
Step 1: Prepare Your Wood
- Select Your Wood: Start with a piece of hardwood. A good starting dimension for the main body of the push block is approximately 6 inches long, 3.5 inches wide, and 1.5 inches thick. This is roughly the size of a standard 2×4.
- Cut to Size: Using your table saw, cut your chosen hardwood to the desired dimensions. Ensure all cuts are square.
Step 2: Shape the Main Body
- Mark the Handle Area: On the top surface of your wood block, measure and mark where the handle will attach. Leave a few inches at the front (the end that will push the wood) clear for the pushing surface.
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Cut the Handle Slot: This is where the table saw is crucial. You’ll want to create a slot to receive the handle.
- Method A (Dovetail Slot – More Advanced): If you have a router and a dovetail jig, you can cut a dovetail slot. This provides a very secure connection.
- Method B (Straight Slot with Tabs): A simpler method involves cutting a slot with your table saw. You’ll make several parallel cuts into the wood block to create a channel. Then, you’ll remove the waste. This can be done with a dado blade if you have one, or by making multiple passes with a standard blade, carefully adjusting the fence for each cut. The key is to leave two “tabs” on either side of the slot to hold the handle.
- Method C (Simple Mortise): You can also cut a simple rectangular mortise using a drill and chisel, or with a router.
Let’s focus on Method B for its accessibility. Imagine your 1.5″ thick block. You want to create a slot about 1 inch deep. Make a series of cuts, say, 1/4 inch apart, stopping about 1 inch from the bottom. Then, carefully remove the slivers of wood between the cuts with a chisel or a sturdy knife. The goal is a channel that will accept the handle.
Step 3: Create the Handle
- Select Handle Wood: Use a piece of hardwood for the handle, approximately 5-6 inches long, 1.5 inches wide, and 3/4 inch thick.
- Shape the Handle:
- Tapering: To make it more ergonomic, you can taper the edges of the handle.
- Creating Tabs: If you used Method B for the slot, you’ll need to create corresponding “tabs” on the handle that will fit into the slots you cut. This means leaving a portion of the handle wider than the slot opening. For example, if your slot is 1/4 inch wide, you might leave the middle of the handle 3/8 inch wide to engage with the sides of the slot.
- Cutting the Handle Slot: Now, use your table saw again to cut the handle to fit into the prepared slot in the main body. Make sure the width of the handle, where it will fit into the slot, is precisely the width of the slot you cut.
Step 4: Assemble the Push Block
- Dry Fit: Before gluing, test fit the handle into the slot in the main body. Ensure it slides in smoothly and is snug.
- Apply Glue: Apply wood glue to the sides of the handle that will be inserted into the slot.
- Insert Handle: Carefully insert the handle into the slot.
- Clamp: Clamp the two pieces together firmly.
- Secure with Screws (Optional but Recommended): For added strength, you can drill pilot holes and countersink screws from the underside of the main body up into the handle. Use screws that are about 1 inch long.
- Clean Up Glue: Wipe away any excess glue that squeezes out with a damp cloth before it dries.
- Allow Glue to Cure: Let the glue cure completely according to the manufacturer’s instructions.
Step 5: Add the Grip Material
- Cut the Grip: Cut a piece of your chosen grip material (rubber, cork, etc.) to fit the bottom surface of the push block. It should be slightly smaller than the base of the block to avoid material creeping over the edges.
- Attach the Grip:
- For Rubber/Cork: Apply contact cement to both the bottom of the push block and the grip material. Let the cement become tacky according to the instructions, then carefully press the grip material onto the block, ensuring it’s centered.
- For Double-Sided Tape: Apply heavy-duty double-sided tape to the bottom of the push block, ensuring full coverage. Peel off the backing and carefully press the grip material onto the tape.
- Secure (Optional): For extra security, especially with rubber, you can add a few small screws from the underside, ensuring they don’t protrude through the gripping surface.
Step 6: Finishing Touches
- Round Over Edges: Use a router with a roundover bit to soften any sharp edges on the push block and handle. This makes it more comfortable to hold. If you don’t have a router, you can achieve a similar effect with sandpaper.
- Sand: Sand all surfaces smooth.
- Optional: Add a Lip: Some woodworkers like to add a small lip or flange to the pushing surface of the block. This lip helps engage the edge of the workpiece, providing better control and preventing the block from slipping. You can achieve this by making a slight angle cut or adding a small strip of wood.
Your DIY table saw push block is now ready!
Alternative Design: Simple Angled Push Block
This is another excellent and very popular design, often referred to as a table saw push guide. It’s simpler to construct and offers a great way to keep your workpiece firmly against the fence.
Materials and Tools:
Same as above, with the exception of needing to cut an angled slot for the handle.
Steps:
- Prepare Wood: Cut your main block (e.g., 6″ x 3.5″ x 1.5″).
- Mark the Angle: On the pushing face of the block (the face that contacts the wood), measure down from the top edge about 1/2 inch on the side furthest from the fence. Draw a line from this point to the top edge on the side closest to where the fence will be. This creates the angle.
- Cut the Angle: Set your table saw blade to a bevel (e.g., 10-15 degrees). With the fence set appropriately, rip the block along this angled line. This creates the angled pushing surface.
- Create the Handle Slot: Now, on the top surface, you’ll create the slot for the handle. The slot should be angled to match the pushing surface. This can be achieved by:
- Tilting the Blade: If you have a tilting blade on your table saw, you can tilt the blade to match the angle of your pushing surface, then make the slot cuts as described in Step 2, Method B.
- Using a Router: A router with a straight bit is excellent for this. You can use a fence attachment or a template to guide the router and cut the angled slot.
- Create and Attach the Handle: Follow Steps 3, 4, and 5 from the T-handle design to create and attach the handle. Ensure the handle also has an angled slot to mate with the angled body.
- Add Grip: Attach grip material to the bottom.
- Finishing Touches: Round over edges and sand.
This angled design is particularly effective as a table saw push guide because the angled pushing surface naturally guides the wood against the fence.
Advanced Push Block Jigs and Considerations
While the designs above are excellent for everyday use, you might encounter situations where a more specialized push block jig is beneficial.
- Push Blocks for Table Saw Sleds: If you use a crosscut sled, you might want a push block designed to be used with the sled’s runners.
- Adjustable Push Blocks: Some designs allow for the pushing surface to be adjusted for different stock thicknesses or angles.
- Push Blocks with Multiple Gripping Surfaces: Having different angles or surfaces can be useful for various cuts.
When considering table saw accessories, a well-made push block is right up there with the best. It’s a safety push block table saw essential.
Maintaining Your Push Block
Like any woodworking tool, your DIY push block will benefit from occasional maintenance.
- Inspect the Grip: Check the rubber or cork grip periodically. If it becomes worn or loses its grip, replace it.
- Check for Damage: Ensure the wood hasn’t split or cracked, especially around the handle.
- Cleanliness: Keep the pushing surfaces clean. Sawdust and grime can reduce friction and control.
Safety First: Using Your Push Block Correctly
Even with a perfectly crafted homemade table saw push block, proper usage is key.
- Always Use It: Make it a habit. Every time you cut, use your push block or a push stick. Don’t rely on your fingers.
- Maintain Downward Pressure: Apply firm, consistent downward pressure on the workpiece. This is what prevents lifting and kickback.
- Keep Hands Behind the Blade: Position your hands on the push block so they are always behind the path of the blade.
- Don’t Force It: If the wood is binding, stop the saw and address the issue. Don’t try to force it through with the push block.
- Use Appropriate Block for the Job: For very thin stock, a traditional push stick might be more appropriate.
- Keep the Table Saw Clean: A clean table surface ensures smooth operation.
A table saw push stick is a general safety tool, but a well-designed push block offers superior control and safety for most operations.
Frequently Asked Questions (FAQ)
Q1: What is the best wood to use for a table saw push block?
A1: Dense hardwoods like maple, oak, or cherry are ideal. They are durable and provide a smooth, stable surface.
Q2: Can I use a piece of scrap wood from my workshop?
A2: Yes, as long as it’s a hardwood and in good condition, scrap wood can be perfect for making a push block. Avoid softwoods like pine.
Q3: How big should a table saw push block be?
A3: A common size for the main body is around 6 inches long, 3.5 inches wide, and 1.5 inches thick. The handle length can vary based on your hand size and preference, but around 5-6 inches is typical.
Q4: What is the purpose of the rubber or cork on the bottom of the push block?
A4: The rubber or cork provides added friction and grip, preventing the push block from slipping on the workpiece. It also helps apply downward pressure more effectively.
Q5: Is a push block better than a push stick?
A5: For most operations, a push block offers superior safety and control due to its ability to apply downward pressure and keep your hands further away from the blade. Push sticks are still useful for very thin materials or when you need to push the workpiece completely past the blade.
Q6: How do I prevent kickback when using my table saw?
A6: Use a push block or push stick, ensure your riving knife and anti-kickback pawls are in place and functioning, keep your workpiece against the fence, and never cut freehand.
Q7: Can I make a push block for my miter saw or other tools?
A7: Yes, the principles of using a push block for safety and control apply to other power tools like miter saws, band saws, and even routers. You can adapt these designs for other tools.
Q8: What is a table saw push guide?
A8: A “table saw push guide” typically refers to a push block designed to help guide the workpiece along the fence, often with an angled pushing surface. Our second design discussed fits this description perfectly.
By following these steps and prioritizing safety, you can easily construct a reliable and effective DIY table saw push block that will be a valuable addition to your table saw accessories. Happy woodworking!