One of the basic essentials for safely using a table saw is a good push stick. I’ve tried several different versions of varying sizes and with different features, but I’ve struggled with how comfortable it feels while also having a sufficient level of control over the workpiece. I have finally found a design I really like, which was also really simple to make.
The design is based off the very excellent one made by Drew Fisher from the YouTube channel Fisher’s Shop (website and YouTube video). Drew provided a pdf template of his design (link on his video), which I used as the start for mine. After transferring the shape onto some scrap pallet wood, I cut out the shape using my coping saw. I didn’t have a piece of scrap wide enough so I temporarily glued an extra piece on while drawing out the design and cutting it out.
Once I had the shape fully cut out, I sanded it to make it comfortable to hold – I intend to use this a lot so want to make sure that it feels good in the hand. I drilled a hole in the top of the handle and a complimentary one in the extra handle piece to then glue a dowel into. I added glue into the joint and clamped the two pieces of the push stick together. While the glue dried, I cut a strip of pallet wood the same width as the push stick and an extra block to fit to the back of the push stick to guide a workpiece into the saw blade. I glued the two extra pieces onto the bottom of the push stick and once the glue dried, gave it another sanding to ensue there were no rough edges.
I tested the push stick out running some scrap wood through the table saw and I am very impressed with the functionality and how comfortable it is to use. The handle is at a good angle for my wrist and the catch block at the back hooks onto the edge of a workpiece very nicely. I also like that the long flat base provides lots of downward pressure to ensure the workpiece remains flush with the table – something I’ve struggled with previously using simple plastic push sticks. The front of the strip of wood on the bottom sits slightly back from the front under the point, which gives me a birds mouth-style option as well (although I have yet to need that functionality). When the push stick gets worn out in future, I can also simply replace the bottom strip of wood, using the flat back of the push stick against the back of my table saw mitre sled to cut off the damaged base piece. An ingeniously simple design – thanks Drew! 🔨
The Woodworking Scientist 