Push Stick Table Saw Template – Crafting Your Ultimate Safety

A push stick table saw template is a woodworking jig used to create custom push sticks, essential safety tools for guiding workpieces through a table saw. Utilizing a template ensures consistent, ergonomic, and effective push stick designs, significantly enhancing control and reducing the risk of kickback or injury during cuts.

Making your own push stick from a template allows for personalized grip and optimal design, making your woodworking safer and more precise.

Every woodworker knows the exhilarating hum of a table saw, but also the deep respect it commands. It’s one of the most versatile and powerful tools in the shop, capable of incredible precision – and potential danger if not handled with care. If you’ve ever felt a little uneasy making those last few inches of a rip cut, or struggled to maintain control over a narrow piece, you’re not alone.

The good news is, there’s a simple, effective solution that elevates both your safety and your accuracy: a well-designed push stick. But not just any push stick. We’re talking about a custom-made one, crafted using a reliable push stick table saw template.

In this comprehensive guide, we’ll dive deep into why a custom push stick is a game-changer, how to create your very own durable push stick table saw template, and the best practices for using it to make push sticks that fit your hand and your work perfectly. Get ready to transform your table saw experience, making it safer, more confident, and ultimately, more enjoyable.

Why a Custom Push Stick is a Game-Changer for Table Saw Safety

Safety at the table saw isn’t just about wearing safety glasses; it’s about having the right tools and knowing how to use them. A push stick is a fundamental safety device, keeping your hands away from the spinning blade.

But why go through the effort of making one from a push stick table saw template when you can buy one off the shelf?

Beyond Store-Bought: The Custom Advantage

Store-bought push sticks are a good starting point, but they’re designed for the average hand and average cut. Your hands, your projects, and your comfort are unique.

A custom push stick, made using a template, allows you to:

Optimize Ergonomics: Design a handle that fits your grip perfectly, reducing fatigue and improving control.
Tailor to Your Needs: Create different push sticks for different tasks – long ones for rip cuts, specialized ones for thin stock.
Enhance Durability: Choose stronger, more sustainable materials that will withstand repeated use and accidental contact with the blade.

Mitigating Kickback and Protecting Fingers

The primary role of any push stick is to keep your fingers far from the blade. A well-designed push stick does more than just push; it controls the workpiece.

By applying downward pressure and forward momentum, you prevent the workpiece from lifting or twisting, which are common causes of dangerous kickback.

A solid grip on the workpiece ensures it stays flat against the table and fence.
The extended reach keeps your hands safely away from the saw’s most dangerous zone.
Using a custom template helps you create consistent designs, reinforcing good safety habits.

Understanding the Anatomy of an Effective Push Stick

Before you start making your push stick table saw template, it helps to understand the key components that make a push stick effective.

Each part plays a crucial role in safety and control.

The Handle: Ergonomics for Control

The handle is where you connect with the push stick. Its design directly impacts your comfort and ability to control the workpiece.

Shape: A comfortable, ergonomic curve or pistol grip is often preferred over a straight stick.
Thickness: Thick enough to provide a secure grip without causing hand strain.
Length: Sufficiently long to keep your hand clear of the blade at all times, even with long rip cuts.

The Foot: Gripping Power

The “foot” is the part that rests on top of your workpiece, providing downward pressure.

Surface Area: A larger foot provides better distribution of downward pressure, preventing the workpiece from lifting.
Material: Some woodworkers add non-slip material like sandpaper or rubber to the foot for extra grip.

The Heel: Pushing Through

The “heel” is the back-most part of the push stick, designed to engage the trailing edge of the workpiece.

Hook: A small hook or notch on the heel catches the end of the board, ensuring positive feed through the blade.
Strength: This part takes the most direct force, so it needs to be robust and resist breaking.

How to Create Your Own Push Stick Table Saw Template

Making a durable push stick table saw template is an excellent project in itself. It’s a rewarding step that ensures you can replicate your favorite push stick design whenever you need a new one.

This section outlines the process, providing a clear push stick table saw template guide.

Materials You’ll Need

For your template, choose a stable and durable material. This isn’t the final push stick, but a pattern.

Material: 1/4″ or 1/2″ MDF (Medium-Density Fiberboard), plywood, or even hardboard are excellent choices. MDF is often preferred for its stability and ease of cutting.
Tools: Pencil, ruler, compass (optional for curves), jigsaw or bandsaw, sandpaper, and a drill for hanging.

Designing Your Template: Key Dimensions

This is where you bring your ideal push stick to life. Sketch out your design on the chosen template material.

Overall Length: Aim for 12-18 inches. This keeps your hands safely away from the blade.
Handle Dimensions: Draw a comfortable grip. A common handle width is 1.5-2 inches, with enough space for your fingers.
Foot Length & Width: Design a foot that’s 4-6 inches long and at least 1.5 inches wide for good workpiece contact.
Heel Depth: A 1/2-inch to 3/4-inch deep heel hook is usually sufficient to catch the end of the board.
Blade Clearance: Ensure the main body of the push stick is narrow enough (e.g., 3/4″ to 1″) to pass between the blade and the fence for typical rip cuts.

Cutting the Template Itself

Accuracy here is key, as this template will guide future push sticks.

Transfer Design: Carefully draw your final design onto your template material using a ruler and pencil.
Rough Cut: Use a jigsaw or bandsaw to cut outside your lines. Don’t try to be perfect yet.
Refine Edges: Use sandpaper, a sanding block, or a spindle sander to carefully sand right up to your drawn lines. Smooth, accurate edges are crucial for precise tracing later.
Drill Hole: Drill a small hole in one corner for hanging your template in your workshop.

Step-by-Step: Using Your Push Stick Template for Precision

Once your template is complete, making multiple push sticks becomes a straightforward process. This section covers push stick table saw template best practices for replication.

Selecting Your Push Stick Material

For the actual push stick, you want a material that’s strong enough to push without flexing, but also soft enough not to damage your saw blade if accidental contact occurs.

Wood Choices: Plywood (Baltic Birch is excellent), MDF, or even a dense hardwood like maple or oak are ideal. Pine or fir can work for lighter duty but may wear faster.
Thickness: 1/2″ to 3/4″ thick is a good range for a sturdy push stick.
Sustainable Push Stick Table Saw Template: Consider using high-quality scrap wood from previous projects. This makes your push sticks virtually free and eco-friendly push stick table saw template creations.

Tracing and Rough Cutting

This is where your template shines, ensuring consistency.

Secure Template: Place your finished template onto your chosen push stick material. Use clamps or double-sided tape to hold it firmly in place.
Trace: Use a sharp pencil to trace around the entire perimeter of the template. Be precise.
Rough Cut: Again, use a jigsaw or bandsaw to cut just outside your traced line. Leave a small amount of material for final shaping.

Refining with a Router or Bandsaw

Achieving smooth, accurate edges is essential for comfortable use and good control.

Router Table Method (Recommended): Attach your template to the rough-cut push stick blank using double-sided tape or screws in waste areas. Use a flush trim router bit with a bearing that rides along your template. This creates a perfect replica.
Bandsaw Method: Carefully cut to your lines on the bandsaw. This requires a steady hand and a sharp blade.
Spindle Sander/Drum Sander: For those without a router table, a spindle sander or drum sander can be used to refine the edges right up to your traced lines.

Finishing Touches

A little extra effort here makes a big difference in comfort and longevity.

Sanding: Sand all edges and surfaces smooth. Start with 120-grit, then move to 220-grit for a comfortable feel.
Edge Rounding: Lightly round over the edges of the handle and foot with sandpaper or a router with a small round-over bit. This improves grip and comfort.
Optional Finish: Apply a coat of shellac, polyurethane, or Danish oil. This protects the wood and makes it easier to clean.

Advanced Tips for Your Custom Push Stick

Once you’re comfortable with the basics, consider these push stick table saw template tips to further enhance your custom creations.

Adding Grip Enhancements

A secure grip on the workpiece is paramount.

Adhesive Sandpaper: Apply a strip of coarse (60-80 grit) adhesive-backed sandpaper to the bottom of the push stick’s foot for extra traction.
Rubber Matting: Cut a piece of non-slip rubber matting (like shelf liner) and glue it to the foot. This provides excellent grip and is less abrasive than sandpaper.

Multi-Purpose Designs

Don’t stop at just one design. Your push stick table saw template can be adapted.

Thin Stock Push Stick: Create a narrower push stick specifically for guiding thin workpieces, ensuring it doesn’t rub against the fence.
Long Rip Push Stick: Design a longer push stick for those extended rip cuts, giving you more reach and keeping your body safely positioned.
Push Block Hybrid: Combine elements of a push stick and a push block for certain operations, offering both pushing power and downward pressure.

Eco-Friendly Material Choices

Embrace sustainability in your workshop.

Scrap Wood: As mentioned, the best material for a push stick is often a sturdy piece of scrap wood you already have.
Reclaimed Materials: Look for reclaimed hardwoods or high-quality plywood from old furniture or pallets (ensure they are clean and nail-free). This is truly an eco-friendly push stick table saw template approach.

Caring for Your Push Stick and Template

To ensure your custom push sticks and your valuable template last, proper care is essential. This is your push stick table saw template care guide.

Regular Inspection and Maintenance

Your push stick is a wear item, meant to be sacrificed to protect your hands.

Check for Wear: Regularly inspect the heel and foot for excessive wear, splintering, or signs of blade contact. If the heel is significantly chewed up, it’s time for a new one.
Clean: Wipe down your push stick to remove sawdust and grime. This helps maintain grip.
Replace When Needed: Don’t hesitate to replace a damaged push stick. They are inexpensive to make and vital for safety.

Storage Best Practices

Keep your template and push sticks accessible yet protected.

Template Storage: Hang your push stick table saw template on a pegboard near your table saw or store it flat to prevent warping. Protect its edges from dings.
Push Stick Storage: Keep your push sticks readily available at your table saw station. A simple hook or magnetic strip works well.

Troubleshooting Common Push Stick Issues

Even with a custom push stick, you might encounter minor issues. Here are solutions to common problems with push stick table saw template designs or usage.

Slipping and Loss of Control

If your push stick isn’t gripping the workpiece effectively, it defeats its purpose.

Solution: Ensure you’re applying sufficient downward pressure. Add grip material (sandpaper or rubber) to the foot of your push stick.
Check Heel: Make sure the heel is properly engaging the trailing edge of the workpiece, not just sliding over it.

Excessive Wear and Tear

While push sticks are sacrificial, they shouldn’t disintegrate after a few cuts.

Solution: If your push sticks are wearing out too quickly, consider using a denser wood (like Baltic Birch plywood or hardwood) for your next batch.
Rethink Technique: Ensure you’re not intentionally running the push stick into the blade. While minor contact is expected, heavy impacts indicate a technique issue or misaligned fence.

Template Warping or Damage

Your template is your master pattern; protect it!

Solution: If your template warps, it’s likely due to moisture or improper storage. Store it flat or hang it in a stable environment. If damaged, it’s worth making a new one to ensure future accuracy.

Frequently Asked Questions About Push Stick Templates

Why can’t I just buy a push stick?

While you certainly can buy a push stick, a custom one made from a push stick table saw template offers superior ergonomics, better control, and the ability to tailor designs for specific tasks. It leads to a safer and more comfortable woodworking experience that off-the-shelf options rarely match.

What’s the best material for a push stick?

For durability and good balance, 1/2″ or 3/4″ Baltic Birch plywood or a dense hardwood like maple or oak are excellent choices. MDF can work but is less durable against repeated blade contact. Using scrap wood is an ideal sustainable push stick table saw template practice.

How often should I replace my push stick?

You should replace your push stick as soon as the heel or foot shows significant wear, splintering, or damage from blade contact. A compromised push stick can lose its effectiveness and become a safety hazard. Since you have a template, making new ones is quick and easy.

Can I use a push stick template for other jigs?

Yes, the concept of using a template for precise, repeatable cuts is fundamental to many woodworking jigs. While this template is specific to push sticks, the skills you gain in creating and using it can be applied to making templates for other shop jigs, such as sleds or specialized fixtures.

Is an eco-friendly push stick really better?

An eco-friendly push stick table saw template approach means utilizing scrap wood or reclaimed materials, which reduces waste and your environmental footprint. Beyond the ecological benefits, using durable, high-quality scrap often results in a better, longer-lasting push stick than cheaper new materials.

Push Your Craft Forward, Safely!

There you have it – a complete guide to understanding, creating, and utilizing a push stick table saw template. Investing your time in making this simple jig is one of the smartest decisions you can make for your workshop.

It’s not just about pushing wood; it’s about pushing your capabilities, your confidence, and most importantly, your safety to new heights. By taking control of your tools and creating custom solutions, you embody the true spirit of a skilled woodworker.

So, grab that scrap wood, design your perfect push stick, and make your next table saw session the safest and most precise yet. Stay safe, stay smart, and keep those fingers where they belong!

Author
Recent Posts

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.