How to Make Push Sticks for Safer Woodworking

Push sticks are indispensable tools in any woodworking shop, designed to keep fingers safely away from spinning blades while feeding material through cuts on table saws, bandsaws, routers, and jointers. These simple devices allow precise control over narrow or short workpieces, preventing kickback and injuries. By crafting your own from scrap plywood or lumber, you save money and customize grips for comfort. This guide explores various designs, construction techniques, and best practices drawn from proven workshop methods.

Why Every Woodworker Needs Push Sticks

Safety standards from organizations like the Occupational Safety and Health Administration (OSHA) emphasize guarding hands during ripping operations on table saws, where blades exceed 6 inches in diameter. Push sticks extend your reach, applying downward pressure and forward motion without risking fingertips. They are mandatory for cuts under 6 inches wide or when using dado sets.

Beyond compliance, push sticks enhance accuracy. Commercial versions often cost $20–$50, but DIY alternatives use remnants from previous projects, costing nothing. Plywood is ideal due to its layered strength, resisting splits better than solid wood. Common thicknesses range from 1/2 to 3/4 inch for durability without bulk.

Basic Principles of Effective Push Stick Design

A good push stick features three key elements: a secure handle for two-handed control, a non-slip bottom surface for grip, and a leading-edge notch or heel to hook and advance the workpiece. Handles should ergonomically fit the hand, often 4–6 inches tall with rounded edges to prevent fatigue. The base benefits from sandpaper or rubber for traction on wood or metal tables.

Length typically spans 10–15 inches, balancing leverage with maneuverability. The heel, about 1–2 inches wide, engages the trailing end of the board, pushing it past the blade while your hand stays 8–12 inches back. Test designs on scrap to refine ergonomics—wider handles suit larger hands, while slimmer profiles aid precision on bandsaws.

• Grip surface: Glue sandpaper or cork to the base for friction.
• Heel design: 90-degree notch for table saws; angled for jointers.
• Material choice: Baltic birch plywood for strength; avoid softwoods prone to splintering.

Simple Scrap Wood Push Stick

Start with the easiest design: trace an existing commercial stick onto 3/4-inch plywood scrap. This method duplicates proven shapes instantly. Mark a 12-inch length with a 5-inch handle height. Cut a 1-inch heel notch at the front using a bandsaw or jigsaw.

Smooth edges with a belt sander or rasp. Drill a 1/4-inch hole near the handle top for hanging storage. Attach 80-grit sandpaper to the base with spray adhesive. This stick excels on table saws for ripping 2x4s or plywood strips, providing smooth forward pressure.

1. Select a 6×12-inch plywood rectangle.
2. Sketch handle curve and heel notch.
3. Cut with bandsaw; sand to shape.
4. Add grip tape; test on scrap.

Ergonomic Handle Push Block

For broader surfaces like router tables or wide rips, build a push block. Cut a 3.5×9-inch plywood base. Laminate a 2×2 scrap for the handle, screwing and gluing it centrally. Contour the top for palm fit using a spokeshave or router.

Line the bottom with full-sheet sandpaper, trimmed flush. This design distributes weight evenly, ideal for planers or sanders. Variations include angled heels for tapered push blocks, aiding featherboards in setups.

Advanced Plywood Template Push Stick

Downloadable templates ensure repeatability. Print a full-scale pattern on paper, glue it to 1/2-inch plywood blanks stacked together. Bandsaw the stack for multiples in one pass. This yields identical sticks with ergonomic curves: a swooping handle and precise 1/2-inch heel.

Smooth with a disc sander, rounding edges via router for comfort. These excel on jointers, where the extended heel maintains even pressure. Users report 90% preference for homemade over plastic due to better grip and customization.

Customizable Tailstock Push Stick

Elevate safety with an adjustable tailstock version. Mill a dado slot in the stick body for a sliding heel. Embed a threaded insert or nut, secured with wood glue. Insert a bolt through the tailstock piece, allowing height adjustments via wingnut.

This adapts to workpiece thickness, from 1/4-inch plywood to 2-inch hardwoods. Drill guide blocks ensure perpendicular holes. Finish with polyurethane for longevity. Perfect for repetitive production runs.

Push Sticks for Specific Tools

Table Saw Ripping

Use L-shaped sticks with deep notches for narrow rips (<3 inches). Apply pressure 2 inches behind the blade, feeding until the heel clears.

Bandsaw and Scroll Saw

Slimmer profiles with smaller heels prevent binding on curves. Add a top horn for zero-clearance guidance.

Jointer and Planer

Longer blocks with rubber pads hold stock flat, bridging gaps in infeed tables.

Drill Press and Router

Small push pads with V-grooves secure round stock or edges.

Safety Tips and Common Mistakes

Always stop the saw before adjusting sticks. Avoid overlong designs that flex. Replace damaged heels immediately—burn marks signal retirement. Pair with riving knives and featherboards for layered protection.

Mistakes include glossy bases (slippery) or brittle pine (snaps). Test on waste wood simulating real cuts.

• Inspect for cracks pre-use.
• Store off the floor to avoid warping.
• Label types for quick grab.

Materials and Tools Roundup

Scraps: Plywood offcuts, 2x2s.
Adhesives: Wood glue, spray contact cement.
Tools: Bandsaw/jigsaw, sander, drill.
Finishes: Sandpaper (80–220 grit), optional varnish.

FAQs

What wood is best for push sticks?

Plywood, especially Baltic birch, for its stability and splinter resistance. Avoid solid pine or oak that may delaminate.

How do I make a push stick without a bandsaw?

Use a jigsaw, coping saw, or even a handsaw. Finish with files and sandpaper for smoothness.

Are DIY push sticks as safe as store-bought?

Yes, when properly made. Many professionals prefer custom fits for better control.

Can push sticks prevent kickback?

They aid by maintaining contact but pair with riving knives for full prevention.

How often should I replace push sticks?

After blade contact, heavy wear, or cracks. Make extras for rotation.

Building Your First Set: Quick Start Guide

Gather scraps, sketch designs, cut multiples. In 30 minutes, equip your shop fully. Experiment with handle angles—taller for leverage, forward for wrist comfort. These tools transform risky tasks into confident operations.