Dovetail Push Block Handle

About

I wanted a sacrificial push block with a reusable handle and was easy to make a bunch of sacrificial stock material all at once, while also using less material. I think this dovetail handle solves those issues.

Features

• Quick change - just slide the block off when it gets to chewed up or if you want different thickness push blocks depending on the situation.
• No hardware to worry about hitting your blades. Other handles use screws from the bottom.
• Easy to batch out many blocks. They also use less material and take up less space for storage. Make a bunch, different widths, heel heights, and swap the handle to the one you need quickly.

Printing

Model is split into two piece's to achieve optimal surfaces. Epoxy is recommended to glue the two piece's together. Supports are recommended to get smooth fillets on the handle, but are minimal.

Assembly

Remove supports and then smear epoxy into the groove on the top of the dovetail piece. Push the two pieces together and hold it together with a piece of masking tape until cured.

Sacrificial Blocks

This can be done with a table saw or a router table using the matchfit router bit. A router table would be easiest to adjust for a perfect fit, but I cut mine on the table saw, only moving the fence a few times to get a snug fit. If cutting on the table saw, its easiest to cut the angles first, and then trim the 90° shoulders for a snug fit.

You can rip a long piece of wood and then cut it into smaller pieces to batch out a bunch of blocks at once. 

You can print out the dovetail marking gauge to make it easier to set your fence. Cut it oversized and then adjust to cut to the line.

Optional Steps

I chose to spray mine with plastidip after to give a nice rubberized grip after sanding it smooth.