Build a Table Saw Push Block with an Adjustable Heel
A good table saw push block is one of the most useful safety accessories you can keep in your workshop. It provides better control when feeding stock through the blade while helping keep your hands away from the cutting area.
Many woodworkers make their own push blocks from plywood or scrap hardwood. These simple accessories usually include a small heel that catches the back edge of the workpiece and pushes it through the cut.
The problem is that the heel can eventually become worn or damaged from repeated use.
Rather than replacing the entire push block, I came up with a design that uses an adjustable, replaceable heel.
This shop-made table saw push block features a laminated plywood body, a comfortable handle, and a hardboard heel that can be adjusted or replaced whenever necessary.
It's a simple upgrade that makes a handy shop accessory even more practical.
Why Use a Table Saw Push Block?
A push block helps guide a workpiece through a table saw cut while keeping your hands farther from the blade.
Unlike a basic push stick that contacts the back of the stock at a single point, a push block can provide a larger gripping surface and additional downward pressure.
This helps maintain control as the workpiece moves past the blade.
A push block is especially useful when working with narrower boards or shorter pieces that are difficult to guide comfortably by hand.
However, push blocks aren't appropriate for every cut. Always use a push device suited to the operation and maintain the necessary blade guard, splitter or riving knife, and other safety equipment.
An Adjustable Heel Makes This Push Block Different
The key feature of this design is its replaceable hardboard heel.
On a conventional shop-made push block, the heel is often cut directly into the body.
As it becomes damaged, the push block may eventually need to be replaced.
This version uses a separate piece of hardboard that fits into a slot in the plywood body.
A studded knob holds the heel in place.
Loosening the knob allows you to adjust how far the heel extends below the bottom of the push block.
When the heel becomes worn, simply remove it and install a replacement.
This makes the push block easy to maintain without rebuilding the entire accessory.
How to Build the Table Saw Push Block
The push block is made from two layers of plywood glued together to create a thick, sturdy body.
The adjustable heel fits into a slot between the layers, while a threaded insert and knob lock it in position.
Step 1: Cut the Plywood Blanks
Start by cutting two plywood blanks for the body of the push block.
Using two layers makes it easier to create the slot for the adjustable heel.
Rather than cutting a deep slot into a thick piece of material, you can form the opening in the individual blanks before assembly.
Step 2: Make the Slot for the Heel
Lay out and cut the slot that will accept the hardboard heel.
The slot should allow the heel to slide for adjustment without excessive side-to-side movement.
Check the fit with a piece of hardboard before gluing the plywood layers together.
A snug, smooth fit will make the adjustment easier to control.
Step 3: Glue Up the Push Block Body
With the slot prepared, glue the two plywood blanks together.
I used a piece of waxed hardboard inserted into the slot to keep the layers aligned during glueup.
The wax prevents the hardboard from becoming glued permanently in place.
Clamp the assembly securely and allow the glue to dry.
Once the glue has cured, remove the temporary hardboard spacer.
Step 4: Shape the Body and Handle
After the glue dries, cut the push block to its final shape.
The body includes an integrated handle that provides a comfortable grip during use.
To make the handle easier to hold, round over the top edges and handle at the router table.
Smooth any remaining sharp edges and corners.
The goal is a push block that's comfortable to grip and easy to control.
Step 5: Install the Threaded Insert and Knob
The adjustable heel is secured with a studded knob.
Drill the mounting hole for the threaded insert in the push block body.
Install the threaded insert, making sure it is properly seated.
The knob threads into the insert and applies pressure to hold the heel in position.
Step 6: Add the Replaceable Hardboard Heel
Cut a piece of hardboard to fit the slot.
Slide the heel into position and tighten the knob to secure it.
The heel should project far enough below the bottom of the push block to catch the back edge of the workpiece.
Because the heel is adjustable, you can reposition it as needed or replace it when it becomes damaged.
Using the Adjustable Table Saw Push Block
Before making a cut, check that the hardboard heel is securely locked in position.
The heel should engage the trailing edge of the workpiece without interfering with the table saw blade or other equipment.
Hold the push block firmly by its handle and use it to guide the workpiece through the cut.
The heel helps push the stock forward while the body provides a convenient gripping surface.
Replace the Heel When It Wears
Over time, the hardboard heel may become worn or damaged.
That's expected with this type of push block.
When the heel no longer provides reliable contact with the workpiece, loosen the knob and remove it.
Install a new piece of hardboard, adjust its position, and tighten the knob.
There's no need to replace the plywood body.
Shop Safety: Inspect the push block before each use. Make sure the heel is securely clamped and the handle and body are undamaged. Keep the push block clear of the blade whenever possible, and replace any damaged components before continuing. Use the appropriate push device for the cut, and never rely on a push block as a substitute for the saw's other safety features.
A Simple Table Saw Accessory That Lasts
A table saw push block doesn't have to be complicated to be useful.
This design combines a comfortable plywood body with an adjustable hardboard heel that can be replaced whenever it wears out.
The laminated construction makes the slot easy to create, while the threaded knob provides a simple way to secure the heel.
It's a practical shop-made accessory that provides better control at the table saw and eliminates the need to rebuild the entire push block when the heel becomes damaged.
How to Avoid Table Saw Kickback
Kickback is one of the biggest hazards when using a table saw. Learn what causes it, how to position and control your workpiece, and which safety practices can help reduce the risk. These practical tips will help you work more confidently and safely at the table saw.
LEARN TABLE SAW SAFETY → Simple Techniques for Safer Table Saw Cuts
