This project was built and designed by Mark from Gunflint Designs. It’s a clever use of shop leftovers to create durable, ergonomic push blocks that improve safety and control at the table saw.
Instead of buying store-bought push blocks, Mark shows how to build your own using scrap wood and PVC pipe. These customized shop tools are easy to make, cost almost nothing, and can be tailored to your preferences—all while putting your scraps to good use.
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Why Push Blocks Matter
Push blocks are essential for safe work at the table saw, router table, or jointer. They give you better control over the stock while keeping your hands a safe distance from the blade.
Mark emphasizes that even the simplest safety tools can prevent serious injuries. By building your own push blocks, you ensure they fit your workflow, your grip, and the kinds of materials you typically use.
Materials from the Scrap Bin
This build starts with basic offcuts and leftover shop supplies. The handles are made from PVC pipe, a lightweight and tough material that’s easy to shape and modify.
The bodies of the push blocks come from scrap plywood, MDF, or solid wood—whatever is on hand. Mark adds a wooden cleat to the back of one push block to act as a foot, which helps grab and guide the stock more effectively during a cut.
Laying Out and Cutting the Block
Mark begins by cutting his base pieces to size using the table saw. These blocks form the working surface of the push tool, and he keeps the edges square for consistent pressure and stability.
To fit the PVC handles, curved notches are traced and cut into the blocks. This allows the pipe to nest cleanly into the top and gives a comfortable hand grip when pushing forward.
Edges are rounded over and sanded smooth before the PVC is installed. This prevents sharp corners from digging into your hand and gives the push block a cleaner, more comfortable feel in use.
Installing the PVC Handles
The PVC handles are cut to length and set into the notches with glue and screws. Mark adjusts the handle placement for a natural grip, ensuring it feels right in hand and sits at the right height above the block.
Once installed, the PVC offers a durable, moisture-resistant grip that’s surprisingly comfortable. It’s an inexpensive alternative to hardwood or plastic handles and can be replaced easily if it wears down or cracks over time.
Adding a Wooden Cleat
To improve functionality, a small strip of wood is attached to the rear underside of one push block. This cleat digs into the back of the workpiece as it’s pushed forward, preventing slippage and giving you better control.
Mark carefully aligns the cleat so that it doesn’t interfere with normal cutting operations. The extra traction is especially helpful when working with longer boards or slick stock that might otherwise slide on the table.
Customizing to Fit Your Needs
One of the best parts of this project is how easily it can be customized. You can adjust the length, width, or height of the push blocks to fit your hand size or cutting preferences.
Some woodworkers may choose to add rubber grip tape or non-slip material to the base for extra traction. Others might personalize the handle shape or block angle to better match their workflow.
Mark mentions that you can even add color or labels to keep different push blocks assigned to specific tools or types of cuts. These details may be small, but they add real efficiency to a shop routine.
Safety, Simplicity, and Sustainability
This project checks all the boxes—safety, simplicity, and sustainability. By using scraps and leftover materials, you’re not only saving money but reducing waste and making something genuinely useful.
For newer woodworkers, this is a great beginner project that introduces shaping, layout, and tool setup. For seasoned makers, it’s a quick and satisfying shop upgrade that can be done in an afternoon.
Push blocks may not be glamorous, but they’re a quiet workhorse in any woodworking space. And when they’re made to fit your hand and your work, they become one of the most reliable tools you own.
A Smart Addition to Any Shop
Mark’s approach shows that shop-made tools don’t have to be complicated or expensive to be effective. These PVC handled push blocks are a reminder that even the simplest builds can have a big impact on safety and workflow.
Whether you’re replacing worn-out store-bought models or looking to personalize your shop setup, this project is worth a spot on your to-do list. It’s a fast, affordable way to make woodworking just a little bit better.
You can see all of Mark’s plans here: https://www.gunflintdesigns.com/project-plans.