Can you make a table saw push block? Yes, you absolutely can make a table saw push block, and it’s a fantastic way to improve your table saw safety and achieve cleaner cuts. A homemade table saw push block is an essential woodworking tool that helps keep your hands away from the spinning blade.
Table saws are powerful machines, and while incredibly versatile, they demand respect and the right safety gear. One of the most critical pieces of safety equipment for any table saw user is a good push block. While you can purchase them, creating your own offers several advantages, including customization, cost savings, and the satisfaction of crafting your own woodworking safety tools. This guide will walk you through how to make a table saw push block safely, covering different designs and important considerations.
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Why Use a Table Saw Push Block?
Before we dive into making one, let’s solidify why these simple tools are so important.
- Hand Protection: The primary function is to keep your fingers and hands a safe distance from the table saw blade. This is paramount for preventing severe injuries.
- Consistent Pressure: A good push block helps apply even pressure to the workpiece as it passes through the blade. This leads to cleaner cuts, reduces tear-out, and minimizes the risk of kickback.
- Control: It gives you better control over the wood, especially for smaller or narrower pieces where your fingers might get too close to the blade.
- Blade Alignment: By pushing the wood through with a push block, you can ensure the workpiece stays flush against the rip fence, leading to straighter cuts.
Push Stick Alternatives and the Role of Push Blocks
While push sticks are also valuable safety devices, a push block offers a different kind of control. Push sticks are generally used for the final push of a board past the blade. Push blocks, on the other hand, are designed to be held and manipulated throughout the cut, offering superior control and pressure. They can be used in conjunction with push sticks for ultimate safety. Many woodworkers find push blocks to be superior to basic push stick alternatives for many ripping operations.
Designing Your Own Table Saw Push Block
The beauty of making your own is that you can tailor the design to your needs and the types of cuts you most frequently make. Here are some popular and effective DIY push block designs:
Simple Rectangular Push Block
This is the most basic and arguably the most common design. It’s easy to make and highly effective.
Materials Needed:
- Hardwood scraps (e.g., oak, maple, walnut) – at least 1″ thick
- Wood glue
- Screws (optional, for added durability)
- Sandpaper (various grits)
- Non-slip material (e.g., rubber shelf liner, cork sheet, adhesive-backed sandpaper)
Construction Steps:
- Cut the Stock: Cut a piece of hardwood to your desired dimensions. A good starting point is roughly 6 inches long, 3 inches wide, and 1 to 1.5 inches thick. The thickness is important to ensure a comfortable grip and good control.
- Create a Handle/Grip: This is crucial for usability. You can:
- Chamfer Edges: Using a router with a chamfer bit or a hand plane, bevel all the edges, especially the top one, to create a comfortable place to rest your thumb and fingers.
- Cut a Finger Groove: Using a router with a cove bit or a round-over bit, you can cut a shallow groove along the top edge for your fingers to rest in. This provides excellent grip.
- Add a Handle Block: Glue and screw a smaller piece of wood perpendicular to the main body to act as a handle.
- Add a Non-Slip Surface: This is vital for preventing slippage during use.
- Glue on Rubber: Cut a piece of rubber shelf liner or a thin rubber sheet to fit the bottom of the push block. Apply wood glue or contact cement and press firmly.
- Adhesive Sandpaper: Similar to rubber, cut a piece of coarse-grit adhesive-backed sandpaper and attach it to the bottom.
- Cork: A thin sheet of cork can also provide good grip.
- Assembly (if using multiple pieces): If you’re laminating two thinner pieces of wood to achieve the desired thickness, ensure the mating surfaces are flat. Apply wood glue evenly, clamp them together securely, and let the glue cure completely. You can add screws from the bottom for extra strength, countersinking them so they don’t interfere with the cut.
- Sand and Finish: Smooth all surfaces with sandpaper, starting with a coarser grit and moving to finer grits. You can leave it unfinished, or apply a coat of paste wax or polyurethane for durability and a smoother feel.
Angled Push Block for Ripping
This design is excellent for maintaining constant pressure against the rip fence, especially for long rips. The angled face grips the wood firmly.
Materials Needed:
- Hardwood scraps (e.g., maple, oak) – at least 1″ thick
- Wood glue
- Screws (optional)
- Non-slip material
- Router with a straight bit or dado blade (or a table saw with a dado blade for the groove)
Construction Steps:
- Cut the Stock: Cut two pieces of hardwood. One piece will be the base (e.g., 6″ x 3″ x 3/4″), and the second piece will be the angled part (e.g., 6″ x 3″ x 1″).
- Create the Angle:
- Option 1 (Table Saw): Set your table saw blade to a 5-10 degree bevel. Rip a 6-inch long strip of wood that is 1 inch thick. This will create the angled face.
- Option 2 (Router): Use a router with a straight bit. Set up a jig or use a router table to create a gradual slope or a more defined angled edge on one of the pieces. Alternatively, a dado blade on your table saw can be used to create a channel if you’re building a more complex design.
- Assemble the Pieces: Glue and clamp the angled piece onto the base piece. Ensure the angled face is oriented correctly to push the wood against the fence. If you want extra security, you can pre-drill and insert screws from the bottom of the base into the angled piece.
- Add Non-Slip Surface: Apply your chosen non-slip material to the angled face of the push block. This is where the contact with the wood will be.
- Create a Handle: As with the simple rectangular block, add a comfortable grip by chamfering edges or cutting a finger groove.
- Sand and Finish: Smooth all surfaces.
The “Gripper” Style Push Block
This is a more advanced but highly effective design that uses a spring-loaded or fixed clamp mechanism to grip the wood. This is fantastic for cross-cutting or when you need extra security.
Materials Needed:
- Hardwood for the body (e.g., 1″ thick maple or oak)
- Hardwood for the fence guide
- Small block of wood for the gripper
- Wood screws
- Small springs (optional, for a more advanced version)
- Non-slip material
- Drill and bits
- Screwdriver
Construction Steps:
- Build the Main Body: Create a sturdy rectangular block, similar to the simple design, with a comfortable handle and a non-slip bottom.
- Create the Fence Guide: Cut a thin strip of hardwood that will act as a guide against the rip fence. This piece should be the same height as the main body. Glue and screw this to the side of the main body.
- Construct the Gripper Mechanism:
- Fixed Gripper: Cut a small block of wood. Attach it to the top of the main body using screws, positioned so it overhangs the edge where the wood will be cut. The bottom of this gripper block should have a non-slip material. This acts as a fixed downward pressure.
- Spring-Loaded Gripper (More Advanced): This involves creating a mortise in the main body to house a pivoting arm or a sliding block. Springs would be used to apply downward pressure. This is a more complex build and often involves precise joinery.
- Attach Non-Slip Material: Apply to the bottom of the main body and the gripper.
- Sand and Finish: Ensure all surfaces are smooth.
Critical Safety Considerations When Making and Using Push Blocks
Creating your own jigs and tools is rewarding, but table saw safety must always be the top priority.
Material Selection
- Hardwood is best: Avoid softwoods like pine, as they can be too easily damaged by the saw blade or wear down quickly. Dense hardwoods like maple, oak, or walnut provide durability and stability.
- Avoid knots and defects: Inspect your wood for any knots, cracks, or other imperfections that could compromise the integrity of the push block.
Design Elements for Safety
- Adequate Thickness: A push block should be thick enough to provide a comfortable grip and substantial enough to push firmly without flexing. At least 1 inch thick is recommended.
- Comfortable Grip: A poorly designed handle can lead to slippage and an unsafe grip. Chamfered edges or finger grooves are highly recommended.
- Non-Slip Surface: This is non-negotiable. Without good grip, the push block can slide off the workpiece, leading to injury. Make sure the non-slip material is securely attached.
- Keep it Free of Sawdust: Regularly clean your push block to ensure optimal grip and prevent the buildup of dust that can interfere with its function.
Table Saw Setup for Safe Operation
- Blade Height: Ensure the blade is raised just enough to clear the workpiece. The standard rule is to have the top of the blade about 1/8″ to 1/4″ above the material.
- Rip Fence: Always ensure the rip fence is parallel to the blade and locked securely. For ripping operations, the push block should maintain contact with the fence.
- Blade Guard and Dust Collection: Use your table saw’s blade guard whenever possible, and connect a dust collection system. While a push block keeps your hands away, the guard offers additional protection.
- Know Your Machine: Familiarize yourself with your table saw’s capabilities and safety features.
Using Your Homemade Table Saw Jigs and Push Blocks
- Always Push Forward: Keep the pressure moving forward through the cut, never sideways or backward.
- Maintain Contact: Keep the push block in firm contact with the workpiece and the rip fence (for ripping).
- Don’t Force It: If the wood is binding, stop the saw. Never try to force a piece through.
- Use Appropriate Push Blocks for Tasks: A simple push block is great for ripping, while an angled push block or a specialized jig might be better for specific tasks. Consider a router table push block for similar operations on a router.
- Clear the Table: Keep your table saw surface clear of scraps and offcuts.
- One Hand at a Time: For safety, only use one push block or push stick at a time.
Popular Table Saw Accessories and Homemade Jigs
Beyond the basic push block, there are many other helpful accessories and homemade table saw jigs you can create to enhance safety and efficiency.
Table Saw Feeder
A table saw feeder, often called a power feeder, is a more advanced accessory that uses motorized rollers to push the wood through the saw. While you can purchase these, some advanced DIYers have created simpler versions or jigs that mimic some of their functions for very specific tasks. However, for general use, a good push block is usually sufficient.
Crosscut Sleds
A crosscut sled is an invaluable jig for table saw operations. It consists of a base that slides in the table saw’s miter slots, with a fence attached perpendicular to the base. This allows for perfectly square crosscuts and provides a surface to push the workpiece with a push block, greatly enhancing safety for these cuts.
Tenon Jigs
These jigs are designed to hold a workpiece securely while it’s being cut on the table saw to create tenons. They often incorporate a way to hold the wood against a fence and a push surface, again highlighting the importance of a push block for controlling the cut.
Box Pushing Jigs
For making box joints or dadoes in a repetitive manner, specialized push blocks or jigs can be made to ensure consistent spacing and depth, all while keeping hands safe.
Table Saw Push Block Designs: A Comparison
Here’s a quick look at how different designs cater to specific needs.
| Push Block Design | Best For | Pros | Cons |
|---|---|---|---|
| Simple Rectangular | General ripping, crosscutting small pieces | Easy to make, versatile, good control | Can be less stable for very long rips |
| Angled Push Block | Long rips, maintaining fence contact | Excellent fence contact, consistent pressure, prevents blade climb | Slightly more complex to make, less versatile for crosscuts |
| “Gripper” Style | Crosscutting, workpieces prone to lifting | Superior hold-down force, very secure | More complex to build, may be overkill for simple tasks |
| Push Block with Handle | All-around use, improved ergonomics | Enhanced comfort and grip, better control | Requires more careful measurement for handle placement |
| Push Block with Finger Groove | All-around use, maximum grip and control | Excellent grip, prevents slipping, comfortable for long use | Requires a router or specific tools to create the groove |
Maintenance and Longevity of Your Push Block
Like any tool, your homemade push block will benefit from a little care.
- Regular Cleaning: Wipe it down after each use to remove sawdust and resin.
- Check the Non-Slip Surface: Periodically inspect the non-slip material. If it starts to wear out or peel, replace it. This is a crucial safety component.
- Inspect for Damage: If the push block ever contacts the blade, inspect it for any damage that could compromise its safety or effectiveness. Minor nicks might be okay, but significant damage means it’s time to make a new one.
- Storage: Store your push blocks in a dedicated spot in your workshop, perhaps in a tool drawer or on a wall-mounted rack, so they are readily accessible and not damaged.
Frequently Asked Questions (FAQ)
Q: What is the best wood to use for a table saw push block?
A: Dense hardwoods like maple, oak, or walnut are best. They are durable and less likely to be damaged by the saw blade.
Q: How thick should my table saw push block be?
A: A thickness of at least 1 inch is recommended for a comfortable grip and good control.
Q: Can I use a store-bought push block instead of making one?
A: Yes, store-bought push blocks are excellent safety tools. However, making your own can be more cost-effective and allows for customization.
Q: What’s the difference between a push block and a push stick?
A: A push stick is typically a thinner piece of wood used for the final push of a board past the blade. A push block is a thicker, more substantial tool designed to be held and manipulated throughout the cut, providing better control and pressure.
Q: How do I make sure my push block doesn’t slip?
A: The most effective way is to add a non-slip surface to the bottom of the push block. This can be done with rubber shelf liner, cork, or coarse-grit adhesive-backed sandpaper.
Q: Is a push block necessary for every table saw cut?
A: While not strictly necessary for every single cut (e.g., very thick stock where your hands can stay a safe distance), using a push block or push stick for any cut where your hands might come close to the blade is highly recommended for table saw safety. They are especially crucial for ripping narrow stock.
Q: Can I use my homemade push block on a router table?
A: Yes, the principles of using a push block apply to router tables as well. You might even consider making a specific router table push block with a slightly different design to optimize for router operations.
Making your own table saw push block is a straightforward and highly rewarding woodworking project. It’s an investment in your safety and the quality of your cuts. By following these guidelines, you can create effective, reliable woodworking safety tools that will serve you well for years to come. Remember, table saw safety is paramount, and a well-made push block is a cornerstone of safe operation.