Looking for a reliable push block design that prioritizes safety? This innovative push block was created by Cody from Craftswright. This guide will help you make a durable and effective push block that keeps your fingers safe!
Materials and Tools Needed:
- Plywood
- Half-inch Forstner bit
- One and three-quarter-inch Forstner bit
- Jigsaw
- File
- Round over bit
- Sandpaper
- CA glue and activator
- Dust collection system
Step 1: Prepare the Stock
Cody starts by preparing two pieces of plywood to create two push blocks simultaneously. He uses the tape and CA glue trick to hold them together, ensuring they won’t accidentally glue to each other.
Step 2: Drill the Holes
Next, he drills out holes in the center part of the stock using a half-inch and a one and three-quarter-inch Forstner bit. He humorously acknowledges the metric versus imperial debate, but ultimately sticks with what works for him.
Step 3: Clear Out the Waste
After drilling, Cody uses a jigsaw to remove the waste material. He notes that while jigsaws don’t always provide the cleanest cuts, they get the job done.
Step 4: Refine the Cuts
With the inside cutout, he refines the edges with a file to ensure smooth transitions between the rounded and flat areas.
Step 5: Shape the Outside
Next, he takes the piece to the bandsaw to cut the outer shape. The result is two push blocks that Cody describes as looking reminiscent of the game Assassin’s Creed.
Step 6: Finish the Edges
After cutting, Cody rounds over the inside edges with a round over bit and leaves the outside edges flat, which is crucial for ensuring the block stays flat on the workpiece.
Step 7: Sanding and Final Touches
He then sands the edges to give them a smooth finish, highlighting a pro tip about reusing worn sanding sponges as backers for sandpaper.
Step 8: Understanding the Design Features
Cody discusses the thought process behind his push block design. He emphasizes that using plywood provides better durability than hardwood due to its alternating grain pattern, making it less prone to breaking. The large hole in the center allows for easy gripping from either side, which is essential for safety and accessibility.
Step 9: Safety First
He stresses the importance of having safety tools readily accessible in the shop. The design of the push block allows the user to hold it comfortably while manipulating stock, which is crucial when working near the table saw.
Step 10: The Pull vs. Push Concept
Cody explains the difference between pulling and pushing the workpiece through the cut. His design encourages pushing, which keeps hands away from the blade, enhancing safety compared to conventional designs.
Final Thoughts
Now that you’ve seen how easy it is to make this push block, Cody encourages everyone to download the free plans from his website and make one for themselves. Remember, practicing good safety techniques is essential in any woodworking shop!