Looking for a simple yet effective woodworking project? This push block design was created by Steve Ramsey from Woodworking for Mere Mortals, and it’s a great addition to any woodworker’s toolkit.
Not only does it keep your fingers safe while using a table saw, but it also helps to ensure cleaner cuts.
Materials and Tools Needed
- Three-quarter inch plywood
- Two by four (for the base)
- Quarter inch plywood (for the cleats)
- Jigsaw
- Drill
- Screws (1 inch and washers)
- Sandpaper
- Clamps
Step 1: Create the Push Stick
To start, you’ll need a push stick to help make the push block. The template for the push stick is included in the plans. Line up the targets, tape them together, and attach the template to your plywood with spray adhesive.
Once secured, cut out the shape using a jigsaw, then peel off the template and sand the edges until you have a comfortable fit in your hand.
Step 2: Assemble the Push Block Handle
Next, we will create the handle assembly for the push block. This consists of the handle and the channel it rides in. Start by raising your saw blade to half the thickness of the plywood and make multiple shallow cuts to create the channel.
Once you have the channel, check the fit with another piece of plywood to ensure it’s snug. After that, cut the handle template and drill starter holes before cutting out the center section with your jigsaw.
Step 3: Attach the Handle
Before gluing the handle into place, drill holes for screws to secure it. Once done, glue the handle into the channel and clamp it to set.
Step 4: Create the Base
For the replaceable base, cut a two by four to your desired length. A common length is nine inches. Attach the handle in the center using screws and washers. The base will serve as the main area of contact with the wood during cutting.
Step 5: Add Cleats
Cut cleats from quarter inch plywood. These should be slightly larger than the thickness of the two by four. Attach the cleats to the back side of the base with screws.
Step 6: Usage and Safety Tips
When using the push block, it’s important to maintain pressure in three directions: down against the table, forward through the cut, and against the rip fence. This will improve safety and cut quality.
Conclusion
With this simple design, you can enhance your safety while improving the quality of your cuts. Remember to always use a push block for safety, especially when making long cuts with your table saw. Enjoy your woodworking!