• Advertise with us
Project by LJackson posted 03-06-2015 03:48 AM 3670 views 10 times favorited 7 comments Add to Favorites Watch

This is my entry for the “Daily Top 3.” The funny thing is, while researching the creation of this super-duper fancy push block, all of the other ones people made all made it into the “Daily Top 3.”

I roughly followed one set of plans, just to get the dimensions, but for the details I just came up with them on my own. I realize now the T-track should have extended to the sides. Also, I made a mistake with the placement of the bolts in the side for the side-car. They were too low, and I could not raise the side-car above the bottom when not in use.

It is made from shop-grade plywood, and some scrap 2×4 wood. The handles were cut out on the bandsaw, and rounded over with a 1/2 inch bit in the router. The grippy bottom is neoprene rubber, 1/8 inch thick. I found a sheet of it on Amazon for I think $14.

I found a number of people with issues screwing in T-track, and ending up cutting down their bolts to fit above the screw heads. Well, I’m here to tell you, an 11/32 inch drill bit can carve out a counter sink for a one inch drywall screw head to sit flush to the bottom of the track. $5 at your favorite box store. I didn’t like the idea of the bolts getting hung up on the screws.

The knobs were made on the drill press. I used my small compass (thanks to John Heisz) to mark out the circles on some scrap 1×3 pine wood, and to mark out six spots around the circle into which I drilled small holes. Then I used my hole saw to cut out the knob. I think I could do better with a jig, as I had to carve out some of the depressions with a file afterward.

I did have some fiddly issues getting the height just right with the three “legs.” Some careful cuts on the table saw rectified those. The neoprene is very grippy. I feel much safer now with small parts, and I feel more accurate, ensuring the piece stays tight to the fence, and doesn’t wander into the blade.

7 comments so far

View Woodwrecker's profile


4211 posts in 3817 days

#1 posted 03-06-2015 03:53 AM

I like yours a heck of a lot better than that plastic blow-molded one that costs an arm and a leg.
Yours actually looks like it should live with a woodworker and I bet it works every bit as good as the store bought one.
Bravo my friend.

View LJackson's profile


295 posts in 1835 days

#2 posted 03-06-2015 04:09 AM

Thanks! The one thing I can say about the store-bought one is that it is very inexpensive compared to the amount of time I put into this. I made two, and it took me two weekends to complete. If I had to charge myself for the work, it’d be like thousands of dollars!

But, on the other hand, I did learn a lot, and did improve my woodworking skills in the process, which is a very big benefit to making it my own.

View robscastle's profile


5633 posts in 2445 days

#3 posted 03-06-2015 06:36 AM

Good work on the design LJackson

I made mine out of frustration from not being able to buy then in AUST
and its still the same today.

Hint hint !!

Mine didnt make the Top Three but I completed the job I wanted to do with them and they are its sitting idle under my table saw.

-- Regards Rob

View badgerhammer's profile


7 posts in 1452 days

#4 posted 03-06-2015 07:25 AM

i’m still trying to figure out what exactly it does. I’m new on the woodworking scene.

View LJackson's profile


295 posts in 1835 days

#5 posted 03-06-2015 11:54 AM

robscastle, if you posted a Grr-ripper project, I did not see it on your list of projects. I also scrolled through your blogs and didn’t see it there, either. You did a good job of hiding it! I think only projects can be top threes.

badgerhammer, it is a push block. The simplest of those just presses onto the wood as you run it through your table saw. This keeps your hands farther from the blade than without. This push block is a bit fancier, in that it can be used to rip small strips. The second photo shows the three legs from the bottom. The far left one in that photo is only 1/4 inch thick, and can be used to support wood to the right of the blade down to that thickness. The neoprene rubber provides friction so that when you push the block into the saw blade, it doesn’t slip backwards.

This is an alternative to using a blade guard. The push block itself is the guard as it is large and as long as your hands are on it and not the wood, you’re (should be) safe.

The center leg can be slid left or right so that it straddles the saw blade. The side-car can be lowered to the table. This is used with larger pieces of lumber, where the three main legs can rest on the wood, and the side-car rests on the table. This is why it doesn’t have any rubber on it; it wants to slide along with the wood.

View robscastle's profile


5633 posts in 2445 days

#6 posted 03-06-2015 12:37 PM

I went for a tour as well an couldnt find them either

May 2012

-- Regards Rob

View bushmaster's profile


3439 posts in 2524 days

#7 posted 03-06-2015 03:29 PM

You have put alot of work into it. I sure it will work well for you.

-- Brian - Hazelton, British Columbia

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics