Table Saw Push Stick Template – Build Your Own Safe & Essential

Working with a table saw is one of the most rewarding aspects of woodworking, allowing you to create precise cuts and tackle ambitious projects. However, it’s also a tool that demands immense respect and unwavering attention to safety. One of the absolute cornerstones of safe table saw operation is the humble push stick.

You might agree that sometimes the best tools in the workshop are the ones you make yourself, tailored to your exact needs. We promise that crafting your own push stick from a reliable

table saw push stick template

isn’t just a simple project; it’s an investment in your safety and the quality of your work. In this comprehensive guide, we’ll walk you through everything you need to know. You’ll learn how to select materials, follow a template, construct your push stick, and use it effectively.

Why a table saw push stick template is Your Workshop MVP

Safety in the workshop is non-negotiable, especially when operating powerful machinery like a table saw. A good push stick keeps your hands far away from the spinning blade, acting as an indispensable extension of your arm. Using a template to build one means you get a proven, ergonomic design that works.

The Undeniable Benefits of a Table Saw Push Stick Template

Why bother making your own when you can buy one? The answer lies in customization and understanding. When you build it, you understand its purpose intimately.

• Enhanced Safety: The primary benefit is keeping your fingers clear of the blade.
• Custom Comfort: You can adjust the grip and size to fit your hand perfectly.
• Specific Task Design: Templates often offer designs optimized for different cuts, like ripping thin stock or pushing larger panels.
• Cost-Effective: Save money by using scrap wood you already have.
• Educational: It’s a great small project for beginners to practice basic woodworking skills.

Safety First: Protecting Your Hands

Let’s be blunt: your hands are your most valuable tools. A table saw blade spins at thousands of RPMs. A momentary lapse in judgment or an unexpected kickback can have devastating consequences.

A well-designed push stick provides a safe buffer. It applies downward and forward pressure, keeping the workpiece flat and against the fence. This control is critical for preventing kickback and ensuring a smooth, safe pass.

Consistency and Precision in Every Cut

Beyond safety, a good push stick significantly improves the quality of your work. It allows you to maintain steady pressure. This means your workpiece stays firmly against the fence and flat on the table.

Consistent pressure translates directly to more accurate and cleaner cuts. This is especially true when ripping narrow strips or when the workpiece is too short to safely push by hand.

Choosing the Right Materials for Your Table Saw Push Stick

The material you choose for your push stick matters for both durability and performance. You want something that’s strong enough to apply pressure but also soft enough not to damage your saw blade if it makes accidental contact.

Selecting the Best Wood for Durability

Hardwoods are generally preferred for their strength and resistance to wear. However, many woodworkers successfully use quality plywood or even MDF for push sticks.

*

Hardwoods:

Maple, oak, cherry, or ash are excellent choices. They are dense and will hold their shape well over time. *

Plywood:

High-quality Baltic birch plywood (¾-inch thick) is a fantastic option. It’s strong, stable, and less prone to splintering than standard construction-grade plywood. *

MDF:

Medium-density fiberboard is dense and dimensionally stable. While it can be a bit heavy and dull tools faster, it’s cheap and provides a smooth surface.

Avoid softwoods like pine or fir. They can splinter easily and won’t hold up to repeated use. Remember, the push stick is sacrificial; it’s meant to take the abuse instead of your hands.

Sustainable and Eco-Friendly Table Saw Push Stick Template Choices

Making your own push stick is inherently eco-friendly because you can use scrap materials. This reduces waste and gives new life to offcuts that might otherwise end up in the bin.

Consider these tips for a sustainable approach:

• Use Scraps: Always check your scrap bin first. A push stick doesn’t require a large piece of pristine lumber.
• Reclaimed Wood: If you have access to reclaimed hardwoods, they make fantastic, durable push sticks.
• Natural Finishes: If you choose to finish your push stick, opt for natural oils or waxes rather than synthetic lacquers. This reduces chemical exposure and makes disposal easier down the line.

Even a small project like this contributes to a more sustainable workshop practice.

Getting Started: Your Table Saw Push Stick Template Guide

Ready to build? The first step is getting your hands on a reliable template. There are many designs out there, from simple stick-style pushers to more elaborate shoe-style designs with multiple handles.

Finding or Creating Your Template Design

You have a few options for acquiring a

table saw push stick template

:

1.

Printable Templates:

Many woodworking blogs and forums offer free, downloadable PDF templates. Print them to scale and glue them onto your chosen stock. 2.

Existing Push Stick:

If you have a favorite push stick, you can trace its outline directly onto your new material. 3.

Design Your Own:

For the adventurous, sketch out a design that feels ergonomic for your hand and provides good pushing leverage. Just ensure it has a comfortable handle, a good “foot” to catch the workpiece, and enough length to keep your hands safe.

When selecting a design, look for one that offers:

* A comfortable handle or grip. * A “heel” or “foot” that can securely hook onto the back edge of your workpiece. * Sufficient length to keep your hand well clear of the blade. * A strong, sturdy profile that won’t flex under pressure.

Tools You’ll Need for This Project

Gathering your tools before you start makes the process much smoother. You won’t need anything exotic for this project.

1. Template: Your chosen paper template or existing push stick.
2. Wood Stock: Your chosen material (¾-inch hardwood or plywood is ideal).
3. Spray Adhesive or Double-Sided Tape: To temporarily attach the template.
4. Band Saw or Jigsaw: For cutting out the shape. A band saw is generally preferred for smoother curves.
5. Drill: To create a starting hole for the jigsaw if needed, or for a hanging hole.
6. Spokeshave, Rasp, or Files: For shaping and refining the handle.
7. Sandpaper: Various grits (e.g., 80, 120, 220) for smoothing edges.
8. Router with Roundover Bit (Optional): For comfortable, rounded edges.
9. Clamps: Essential for holding your workpiece securely.
10. Pencil and Ruler: For marking and checking dimensions.
11. Safety Gear: Eye protection, hearing protection, and dust mask. Always!

Step-by-Step: How to Table Saw Push Stick Template Construction

Now for the hands-on part. Take your time with each step, focusing on accuracy and safety.

Transferring the Template to Your Stock

This is where your chosen

table saw push stick template

comes into play.

1.

Prepare the Stock:

Ensure your wood stock is flat and free of defects. 2.

Attach Template:

If using a paper template, spray a light coat of temporary adhesive on the back of the template or use double-sided tape. Carefully align and press it onto your wood stock. Make sure it’s firmly attached and flat. 3.

Trace (if not using paper template):

If tracing an existing push stick, place it firmly on your stock and trace its outline with a sharp pencil.

Take your time here. A precise transfer makes the cutting process much easier and more accurate.

Cutting Out Your Push Stick Safely

This is the most critical step. Always wear your safety glasses and hearing protection.

1.

Secure Your Workpiece:

Clamp your wood stock firmly to your workbench. Never try to hold it by hand while cutting with a power tool. 2.

Drill Pilot Holes (Jigsaw):

If using a jigsaw for tight interior curves (like a finger hole in the handle), drill a pilot hole large enough for your jigsaw blade to enter. 3.

Cut the Outline:

*

Band Saw:

Carefully guide the wood through the band saw, following the lines of your template. Take smooth, steady cuts. *

Jigsaw:

For a jigsaw, slowly guide the blade along the lines. Be mindful of blade drift and keep the saw perpendicular to the wood. 4.

Leave Waste:

It’s always better to cut slightly outside your line. You can refine the shape later with sanding or a rasp. This is one of the best

table saw push stick template tips

.

Sanding and Finishing for Comfort and Grip

Once the shape is cut, it’s time to refine it. This step is crucial for comfort and preventing splinters.

1.

Shape the Handle:

Use a spokeshave, rasp, or even a sanding block to round over the edges of the handle. This makes it much more comfortable to grip. Aim for a shape that feels natural in your hand. 2.

Rough Sanding:

Start with 80-grit or 120-grit sandpaper to remove any saw marks and further refine the curves. Work your way around all edges and surfaces. 3.

Fine Sanding:

Progress to finer grits (e.g., 180-grit, 220-grit) to achieve a smooth, splinter-free finish. A smooth push stick is safer and more pleasant to use. 4.

Optional Finish:

While not strictly necessary, a light coat of boiled linseed oil or mineral oil can help protect the wood and enhance grip. Let it cure completely before use. Avoid slick finishes that could make the push stick slippery.

Mastering Your New Tool: Table Saw Push Stick Template Best Practices

Having a well-made push stick is only half the battle. Knowing how to use it correctly is paramount for safety and effective cuts.

Proper Hand Placement and Body Stance

Always prioritize your safety.

*

Firm Grip:

Hold the push stick firmly but comfortably. Your grip should be secure, not white-knuckled. *

Body Stance:

Stand slightly to the side of the blade’s path, never directly in line with it. This protects you in case of kickback. *

Downward and Forward Pressure:

Apply constant downward pressure to keep the workpiece flat against the table and forward pressure to move it through the blade. *

Follow Through:

Continue pushing until the workpiece has completely cleared the blade and is either off the back of the table or supported by an outfeed table. Don’t stop pushing prematurely.

When to Use Different Types of Push Sticks

Different cuts often benefit from different push stick designs. This is where creating your own from a

table saw push stick template

truly shines.

*

Standard Push Stick:

Ideal for most ripping operations, providing good control for general lumber. *

Thin Rip Push Stick:

A specialized design, often with a narrower foot, perfect for safely ripping very thin strips of wood without getting your hands too close. *

Push Shoe/Block:

For wider panels, a push shoe or block that covers more surface area offers better control and stability. Some templates combine elements of a shoe and a stick.

Always choose the push stick that provides the most control and keeps your hands furthest from the blade for the specific cut you’re making.

Avoiding Common Problems with Table Saw Push Stick Template Usage

Even with a perfect push stick, mistakes can happen. Be aware of these common pitfalls:

*

Insufficient Pressure:

Not applying enough downward pressure can lead to the workpiece lifting, causing an uneven cut or kickback. *

Stopping Mid-Cut:

Never stop pushing a workpiece halfway through a cut. This increases the risk of kickback or blade binding. If you must stop, turn off the saw and wait for the blade to stop completely before backing out the wood. *

Using Hands Too Soon:

Don’t switch from the push stick to your bare hands too early, especially if the piece is still near the blade. Keep the push stick engaged until the cut is complete and the piece is safely past the blade. *

Worn-Out Push Sticks:

A push stick that is heavily notched or damaged loses its effectiveness. Inspect it regularly.

Longevity and Care: Your Table Saw Push Stick Template Care Guide

Your custom-made push stick is a safety tool; treat it as such. Proper care ensures it remains effective for years.

Inspecting for Wear and Tear

Before every session at the table saw, give your push stick a quick once-over. This is a crucial part of

table saw push stick template best practices

.

*

Check the “Foot”:

The part that contacts the workpiece and pushes it through is most prone to wear. If it’s heavily notched, chipped, or rounded, its effectiveness is reduced. *

Look for Cracks:

Inspect the handle and body for any signs of cracking or splitting. A compromised push stick could fail during a critical moment. *

Examine the Grip:

Ensure the handle is still comfortable and provides a secure grip. If it’s become slick, a light sanding might restore its texture.

Simple Maintenance for Extended Life

A little maintenance goes a long way.

*

Clean Regularly:

Sawdust and pitch can build up on your push stick. Wipe it down after use to prevent buildup that might affect your grip or the stick’s ability to slide smoothly. *

Light Sanding:

If the pushing edge starts to show minor wear, a quick pass with 120-grit sandpaper can sometimes refresh it. *

Storage:

Store your push stick in an easily accessible but protected location. Many woodworkers drill a hole in the handle and hang it near their table saw. This prevents it from getting lost or damaged under other tools.

When to Retire and Replace

There comes a time when even the best push stick needs to be retired. Don’t take chances with a safety device.

*

Significant Damage:

If the “foot” is severely chewed up, if there are deep cracks, or if the stick feels flimsy, it’s time for a new one. *

Loss of Functionality:

If it no longer provides secure purchase on the workpiece or feels unsafe to use, replace it immediately. *

Dullness:

If the pushing edge becomes rounded and can’t effectively grip the wood, it’s time for a new one.

Remember, a new push stick is always cheaper than a trip to the emergency room. Since you have the

table saw push stick template

, making a replacement is a breeze!

Frequently Asked Questions About Table Saw Push Stick Templates

We get a lot of questions about this essential safety tool. Here are some common ones.

How often should I replace my push stick?

There’s no set schedule; it depends on how frequently you use it and how aggressively it gets “used up” by the blade. Inspect it before every use. If the pushing edge is significantly damaged, if it’s cracked, or if you feel it’s no longer providing a secure grip, replace it immediately. It’s a sacrificial tool, designed to protect you.

Can I use plywood for a push stick?

Yes, absolutely! High-quality Baltic birch plywood (¾-inch thick) is an excellent choice for a push stick. It’s strong, stable, and less prone to splintering than standard construction-grade plywood. Avoid thin or low-grade plywood that might flex or delaminate under pressure.

What makes a good push stick design?

A good design typically includes a comfortable handle, a strong “heel” or “foot” to hook onto the workpiece, and enough length to keep your hand safely away from the blade. Many templates incorporate an angled handle for ergonomic grip and a sturdy profile to prevent flexing. The key is secure control and hand safety.

Are store-bought push sticks better than DIY?

Not necessarily. While store-bought push sticks are often well-designed, making your own from a table saw push stick template allows for customization. You can adjust the size and shape to perfectly fit your hand and your specific woodworking needs. Plus, it’s a great way to use up scrap wood and gain a deeper understanding of your tools.

Crafting your own push stick from a reliable

table saw push stick template

is more than just a quick project; it’s a commitment to safety and precision in your workshop. You’ve learned how to choose the right materials, follow a template, construct your push stick, and use it with best practices. Remember, the best tool is the one that keeps you safe and allows you to work with confidence.

So, grab some scrap wood, pick your favorite template, and get building. Your hands will thank you, and your projects will benefit from the added control. Stay safe, stay creative, and keep those fingers far from the blade! Happy woodworking!