How To Make A Table Saw Push Block – Enhance Safety And Precision

Working in the woodshop brings immense satisfaction, but it also demands unwavering respect for our tools. The table saw, while incredibly versatile, is arguably the most dangerous machine in your arsenal. Many woodworkers, from seasoned pros to enthusiastic beginners, understand the constant need to prioritize safety, especially when feeding smaller stock. You know that feeling of unease as your fingers get too close to that whirring blade, right?

At The Jim BoSlice Workshop, we believe that safety and precision go hand-in-hand. That’s why we’re going to show you exactly

how to make a table saw push block

– a simple, yet profoundly effective, jig that will transform your table saw experience. This isn’t just about avoiding accidents; it’s about gaining confidence, making cleaner cuts, and elevating the quality of your work.

In this comprehensive guide, we’ll walk you through everything you need to know: from understanding the crucial design elements and selecting the right materials, to providing a step-by-step tutorial on building your own custom push block. We’ll even share some professional tips for maintenance and address common challenges, ensuring you have a reliable tool that lasts. Get ready to enhance your workshop safety and precision!

Why Every Woodworker Needs a Custom Push Block

If you spend any time at the table saw, you’ve likely experienced the dilemma of safely pushing a narrow piece of wood through the blade. This is where the

benefits of how to make a table saw push block

truly shine. It’s more than just a piece of wood; it’s a critical safety device and a precision enhancer.

Enhanced Safety at the Table Saw

Your hands are your most valuable tools. A push block keeps them a safe distance from the spinning blade, drastically reducing the risk of kickback injuries or accidental contact. This is particularly important when ripping narrow strips or cross-cutting small pieces that offer little surface area for your hands to grip safely.

It acts as a physical barrier, ensuring your fingers never venture into the danger zone.

Improved Cut Quality and Control

Beyond safety, a well-designed push block provides superior control over your workpiece. It applies even, downward pressure, preventing the wood from lifting or chattering as it passes through the blade. This consistent pressure translates directly into cleaner, more accurate cuts.

You can maintain a steady feed rate, which is essential for avoiding burning and achieving smooth edges.

Versatility for Various Projects

A custom push block isn’t just for ripping. It’s incredibly versatile. You can use it for:

• Ripping narrow stock on the table saw.
• Pushing small pieces through a jointer.
• Guiding workpieces on a router table.

Having a reliable push block means you can tackle a wider range of projects with greater confidence and safety.

Understanding Push Block Design: Key Elements for Success

Before we dive into construction, let’s explore the fundamental components that make a push block effective. A solid understanding of these elements is key to following our

how to make a table saw push block guide

effectively. Each part serves a specific function in keeping you safe and your cuts accurate.

The Base Plate

This is the main body of your push block, the flat surface that rests on top of your workpiece. It should be wide enough to provide stable contact with the material you’re cutting, but not so wide that it interferes with your fence or blade guard.

A longer base offers more control, especially for longer rips.

The Handle

The handle is crucial for comfortable and secure grip. It needs to be positioned effectively to allow you to apply both forward and downward pressure. Many designs feature an angled or offset handle to improve ergonomics and visibility.

A good handle prevents your hand from slipping and gives you leverage.

The Cleat (Heel)

Often called the “heel,” the cleat is a strip of wood attached to the back underside of the base. Its primary job is to hook onto the trailing edge of your workpiece. This allows you to push the material completely past the blade without your hand ever getting near the danger zone.

The cleat should be slightly narrower than your base and positioned to provide a positive grip.

Optional Features: Featherboards & Non-Slip Pads

While not essential for a basic push block, these additions can further enhance performance:

• Integrated Featherboards: Small angled cuts in the base can act like a featherboard, applying pressure against the fence for even tighter control.
• Non-Slip Pads: Adding rubber or sandpaper to the bottom of the base can increase friction, preventing the push block from slipping on your workpiece.

Consider these enhancements once you’ve mastered the basic build.

Materials and Tools: Gearing Up to Make Your Push Block

Gathering the right materials and tools is the first step in learning

how to make a table saw push block

. Most of these items are likely already in your workshop, making this a cost-effective and rewarding project.

Essential Materials

You don’t need exotic woods for this jig. Functionality and durability are key.

• Plywood or MDF: A half-sheet of 3/4-inch plywood or MDF (Medium Density Fiberboard) is perfect for the base and handle. Baltic birch plywood is excellent due to its stability and lack of voids.
• Hardwood Scraps: For the cleat, a piece of hardwood like oak, maple, or even a dense pine will provide better durability against repeated contact with workpieces. 3/4-inch thick is ideal.
• Wood Glue: High-quality wood glue (e.g., Titebond II or III) is essential for strong joints.
• Wood Screws: 1-1/4 inch to 1-1/2 inch #8 flat-head wood screws will securely fasten the components.

Tools You’ll Need

You’ll be using common workshop tools to assemble your push block.

• Table Saw or Miter Saw: For cutting the main components to size.
• Jigsaw or Bandsaw: Ideal for shaping the handle. A coping saw can also work for smaller curves.
• Drill/Driver: For pre-drilling pilot holes and driving screws.
• Countersink Bit: To ensure screw heads sit flush or below the surface.
• Router (Optional): For rounding over edges on the handle for comfort.
• Sanding Supplies: Sandpaper (120-grit and 220-grit) for smoothing edges.
• Measuring Tape or Ruler: For accurate measurements.
• Pencil and Square: For marking cut lines.
• Safety Gear: Eye protection and hearing protection are non-negotiable.

Step-by-Step Guide: How to Make a Table Saw Push Block (The Jim BoSlice Way)

Alright, let’s get down to business! This detailed guide will show you exactly

how to make a table saw push block

, from cutting the first piece to final assembly. We’ll also sprinkle in some valuable

how to make a table saw push block tips

to ensure your success.

Step 1: Prepare Your Materials

First, cut your plywood or MDF into the basic shapes for the base and handle.

• Base Plate: A good starting size is about 6-8 inches wide and 12-14 inches long. This offers ample contact area.
• Handle Blank: Cut a piece of plywood roughly 1.5 inches wide and 6-8 inches long. This will be shaped later.
• Cleat: Cut a piece of hardwood about 3/4 inch thick, 1.5 inches wide, and 6-8 inches long.

Remember to always double-check your measurements before cutting.

Step 2: Cut the Base Plate

Using your table saw or miter saw, cut your chosen material (plywood or MDF) to the dimensions you decided for the base.

For example, a 7-inch by 13-inch base is a common and effective size. Use a crosscut sled or miter gauge for accuracy.

Pro Tip: Ensure all edges are perfectly square. Any inaccuracy here can affect the stability of your push block.

Step 3: Create the Handle

Now for the ergonomic part. The handle needs to be comfortable and provide a good grip.

1. On your handle blank, draw the desired shape. A simple, comfortable design is a rectangular piece with rounded ends, or a slightly angled profile.
2. Use a jigsaw or bandsaw to carefully cut along your marked lines. Take your time to get smooth curves.
3. Once cut, sand all edges of the handle thoroughly with 120-grit, then 220-grit sandpaper. If you have a router, a 1/4-inch roundover bit on all edges will make it much more comfortable to hold.

This is where personal preference comes into play. Experiment with a comfortable grip before finalizing the shape.

Step 4: Attach the Handle Securely

The handle needs to be positioned to allow maximum control and safety.

1. Place the handle on the base plate. A good starting point is about 1.5 to 2 inches from the front edge of the base, centered left-to-right. Position it so your hand can comfortably grip it while applying downward pressure.
2. Mark the handle’s position on the base.
3. Apply a generous amount of wood glue to the bottom of the handle.
4. Place the handle back onto the marked position on the base.
5. Pre-drill pilot holes through the handle and into the base. Use a countersink bit to ensure the screw heads will sit flush or slightly below the surface.
6. Drive 1-1/4 inch or 1-1/2 inch wood screws through the handle into the base. Use at least two screws for stability.
7. Wipe away any excess glue with a damp cloth.

Safety First: Make sure your handle is rock solid. A wobbly handle is a hazard.

Step 5: Install the Rear Cleat

The cleat is what pushes your workpiece through the blade.

1. Take your hardwood cleat material. A good size is 3/4 inch thick, 1.5 inches wide, and the same length as your base (e.g., 7 inches).
2. Position the cleat on the underside of the base, approximately 1 to 1.5 inches from the rear edge. Ensure it’s perfectly perpendicular to the long edges of the base.
3. Apply wood glue to the top edge of the cleat where it meets the base.
4. Clamp the cleat in place, ensuring it’s flush with the bottom surface of the base.
5. Pre-drill pilot holes through the top of the base plate and into the cleat. Countersink these holes.
6. Secure the cleat with 1-1/4 inch wood screws, typically three to four screws across the length for maximum hold.
7. Allow the glue to dry completely before use, ideally overnight.

The cleat should be slightly narrower than your base. This prevents it from potentially rubbing against your table saw fence.

Step 6: Refine and Test (how to make a table saw push block best practices)

Once the glue has dried, your push block is almost ready.

• Give the entire push block a final sanding, especially any rough edges.
• You can apply a finish like shellac or polyurethane to protect the wood, though it’s not strictly necessary. Avoid finishes that make the bottom too slippery.
• Before using it on a live project, take some scrap wood and practice. Get a feel for the grip, the pressure, and how it guides the material.

Following these how to make a table saw push block best practices ensures a safe and effective tool for years to come.

Common Problems and Smart Solutions When Making Your Push Block

Even with the clearest instructions on

how to make a table saw push block

, sometimes little issues pop up. Here are some

common problems with how to make a table saw push block

and how to easily fix them.

Wobbly Handle

A loose handle is a safety risk and makes the push block ineffective.

• Problem: The handle feels loose or wobbly after assembly.
• Solution: This usually means insufficient glue, screws that are too short, or not enough screws. Disassemble the handle, clean off old glue, reapply a generous amount of fresh wood glue, and use longer or more screws. Ensure pilot holes are appropriately sized for your screws to get maximum grip.

Cleat Not Gripping

If the cleat doesn’t properly engage the workpiece, it defeats the purpose of the push block.

• Problem: The cleat slides over the workpiece instead of pushing it.
• Solution: The cleat might be too short, or its edge might be rounded. Ensure the cleat has a sharp, square edge. If it’s too short, replace it with a new piece of hardwood that has enough height to engage the stock. You can also add a small piece of sandpaper to the face of the cleat for extra grip.

Push Block Too Light or Too Heavy

The weight of your push block impacts its usability.

• Problem: The push block feels too light, making it hard to apply consistent downward pressure, or too heavy, making it cumbersome.
• Solution: For a push block that’s too light, consider using a denser material for the base (e.g., MDF over lightweight plywood). You can also route out pockets in the underside of the base and glue in lead weights (with appropriate safety precautions). If it’s too heavy, ensure you’re using 3/4-inch stock; going thicker will add unnecessary weight. A slightly larger handle can also help manage a heavier block.

Sustainable Practices & Push Block Care

At The Jim BoSlice Workshop, we advocate for responsible woodworking. Incorporating sustainable practices into your shop, even for small projects, makes a difference. This section covers

sustainable how to make a table saw push block

and essential maintenance.

Choosing Eco-Conscious Materials

Making your own push block is inherently more sustainable than buying a plastic one, but you can go further.

• Reclaimed Wood: Prioritize using scraps from other projects or reclaimed wood for your push block. This reduces waste and gives new life to materials.
• Plywood Alternatives: If buying new, look for plywood or MDF certified by the Forest Stewardship Council (FSC), ensuring it comes from responsibly managed forests.
• Eco-Friendly Adhesives: Choose wood glues with low VOC (Volatile Organic Compound) content.

Maintenance for Longevity

Proper care will ensure your push block remains effective and safe for years. This is your

how to make a table saw push block care guide

.

• Inspect Regularly: Before each use, check for loose screws, cracks in the wood, or a worn cleat.
• Clean Off Sawdust: Accumulations of sawdust can reduce friction. Wipe down your push block regularly.
• Replace Worn Parts: If the cleat becomes rounded or damaged, replace it. If the handle loosens, re-glue and re-screw it.
• Store Properly: Hang your push block on a pegboard or store it in a designated spot near your table saw so it’s always handy and protected from damage.

When to Replace Your Push Block

Even the best-made jigs have a lifespan.

• Excessive Wear: If the base becomes significantly warped, cracked, or the cleat is too worn to be effective, it’s time for a new one.
• Damage: Any significant damage from kickback or accidental contact with the blade means it’s compromised and should be replaced immediately.
• Safety Compromise: If you ever feel your push block is no longer providing adequate safety or control, don’t hesitate. Build a new one.

Frequently Asked Questions About Making a Table Saw Push Block

Here are some common questions we get about this essential workshop accessory.

What’s the best material for a push block?

For the base and handle, 3/4-inch Baltic birch plywood or high-quality MDF are excellent choices due to their stability and strength. For the cleat, a dense hardwood like oak, maple, or even a hard pine is preferred for its durability and resistance to wear.

How thick should a push block be?

A thickness of 3/4 inch for the base is standard and provides sufficient rigidity without being overly heavy or bulky. The cleat should also be around 3/4 inch thick to offer good engagement with the workpiece.

Can I buy a good push block instead of making one?

Absolutely! There are many excellent commercial push blocks available, such as the GRR-Ripper system. However, making your own is a rewarding project, often more cost-effective, and allows for custom ergonomic design to fit your hand perfectly. Plus, it’s a great way to use up scrap wood!

How do I store my push block?

Store your push block near your table saw, preferably hanging on a pegboard or a designated hook. This keeps it readily accessible, prevents it from getting lost or damaged under other tools, and helps maintain its condition.

Is a push stick the same as a push block?

No, they serve similar safety purposes but have different designs and applications. A push stick is typically a long, narrow piece of wood or plastic with a notch at the end to push stock. A push block, as described here, has a larger base and a handle, allowing for downward pressure and greater control, especially for wider or shorter stock, and helps prevent kickback by holding the workpiece down.

Building your own table saw push block is a small investment of time and materials that pays huge dividends in safety and precision. It’s a fundamental jig that every woodworker should have, and crafting it yourself adds a personal touch to your workshop.

By following this guide, you’ve not only learned

how to make a table saw push block

, but you’ve also gained a deeper understanding of workshop safety and efficient woodworking practices. So, take pride in your new, custom-made safety tool. Stay safe, stay creative, and keep those projects flowing with confidence!

• Author
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Jim Boslice

Jim Boslice is a power tool enthusiast who tests, reviews, and shares practical guides to help DIYers and professionals choose the right tools for every project.

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