A push stick is one of the most essential safety tools in any woodworking shop. It keeps your hands away from the blade while guiding wood through a table saw, jointer, or router. Yet many beginners either skip using one or use it incorrectly. This guide covers everything you need to know about push sticks: how to use them safely, how to make your own, what to look for when buying, and common mistakes to avoid.
Why You Need a Push Stick for Table Saw Safety
A table saw blade spins at thousands of RPMs. Even a momentary slip can cause serious injury. A push stick gives you control over the workpiece while keeping your hands at a safe distance. According to the U.S. Consumer Product Safety Commission, table saws cause over 30,000 injuries per year, many involving fingers. Using a push stick dramatically reduces that risk.
Push sticks are especially important when ripping narrow boards. When the workpiece is less than 6 inches wide, your hand is dangerously close to the blade. A push stick lets you apply downward and forward pressure without reaching over the blade. Always use a push stick when the distance between the blade and the fence is less than 6 inches.
How to Choose the Right Push Stick: Key Parameters
Not all push sticks are created equal. Here are the critical factors to consider:
Handle design: Look for an ergonomic handle that fits your hand comfortably. Some have a notch that hooks onto the workpiece, giving you better control. Avoid sticks with sharp edges that can dig into your hand.
Material: Most push sticks are made from hardwood (like oak or maple) or plastic. Hardwood is durable and provides a good grip. Plastic is lighter and often cheaper but can be slippery. Some have rubber grips for extra traction.
Length and angle: A typical push stick is 12–18 inches long. The angle at the tip should be about 30–45 degrees to match the blade angle. A steeper angle works for thicker stock, while a shallower angle is better for thin boards.
Safety features: Some push sticks have a built-in guard that covers the blade area. Others have a replaceable tip. Avoid sticks with metal components that could spark or damage the blade.
Price range: You can find decent push sticks for $5–$15. Premium models with ergonomic handles and rubber grips cost $15–$30. For most hobbyists, a $10 hardwood stick is sufficient.
DIY Push Stick: Step-by-Step Guide to Make Your Own
Making your own push stick is easy and can be done with scrap wood. Here’s a simple design that works well:
Materials: A piece of 3/4-inch hardwood plywood or solid wood, about 12 inches long and 4 inches wide. A pencil, jigsaw or bandsaw, sandpaper, and optional rubber grip tape.
Step 1: Draw the shape. On the wood, sketch a handle that’s about 4 inches long and 1.5 inches wide, with a smooth curve. From the handle, extend a straight body about 8 inches long. At the tip, draw a notch about 1 inch deep and 1/2 inch wide to hook onto the workpiece.
Step 2: Cut the shape. Use a jigsaw or bandsaw to cut along the outline. Take your time on the curves to avoid splintering.
Step 3: Sand the edges. Round over all sharp edges with 120-grit sandpaper, then finish with 220-grit for a smooth feel. Pay extra attention to the handle area.
Step 4: Add grip (optional). Wrap the handle with rubber grip tape or apply a layer of polyurethane for better traction.
Step 5: Test it. Use your push stick on a scrap piece of wood to ensure the notch fits properly and the handle feels comfortable. Adjust the notch depth if needed.
Common Mistakes Beginners Make with Push Sticks
Mistake 1: Using a push stick that’s too short. A short stick puts your hand closer to the blade. Always use a stick at least 12 inches long.
Mistake 2: Pushing from the side. You should push from behind the workpiece, not from the side. Side pressure can cause kickback.
Mistake 3: Not using a push stick for narrow cuts. Even if the board is wide at the start, as you cut, the offcut becomes narrow. Switch to a push stick when the workpiece is less than 6 inches from the blade.
Mistake 4: Using a damaged push stick. Cracks, splinters, or worn notches reduce control. Inspect your push stick regularly and replace it if damaged.
Mistake 5: Holding the push stick incorrectly. Your hand should be on the handle, not on the body. Keep your wrist straight and apply steady pressure.
Push Stick vs. Push Block: What’s the Difference?
Many woodworkers confuse push sticks with push blocks. A push block is wider and often has a handle on top, allowing you to apply pressure from above. It’s better for jointers and planers because it keeps the workpiece flat against the table. A push stick is narrower and works best for table saws, especially for ripping narrow boards. Some shops use both: a push block for initial cuts and a push stick for the final pass. If you can only buy one, start with a push stick—it’s more versatile for table saw work.
FAQ
Q: Can I use a push stick with a miter saw?
A: No, push sticks are designed for table saws, jointers, and routers. For miter saws, use a clamp or hold-down.
Q: How often should I replace my push stick?
A: Inspect it after every few uses. Replace if you see cracks, splinters, or if the notch becomes loose.
Q: Is a plastic or wooden push stick better?
A: Wooden sticks offer better grip and durability. Plastic sticks are cheaper but can be slippery. Many pros prefer hardwood.
Q: Can I make a push stick from plywood?
A: Yes, 3/4-inch plywood works fine. Avoid particleboard as it may splinter.
Q: Do I need a push stick for a bandsaw?
A: Bandsaws have less kickback risk, but a push stick still helps keep hands safe. Use one when cutting small pieces.
Final Thoughts
A push stick is a small investment that pays huge dividends in safety. Whether you buy one or make your own, ensure it fits your hand and the type of cuts you make most often. Start with a simple hardwood stick, practice proper technique, and replace it when worn. Your fingers will thank you.