Power tools are utterly essential to modern carpentry. They make all of our work possible. But using power tools does come with some inherent risk!
On the whole, power tool mistakes range in severity. Some are very innocuous and only result in damage to our materials. But some power tool mistakes pose a severe and immediate risk to our bodies, and so they must be avoided at all cost...
This free guide details the 10 WORST POWER TOOL MISTAKES. To make this video, I had to do some dangerous things with my tools that I would normally never do. But it was important to me that people actually see the ramifications of these risky accidents.
So, I hope that you enjoy and learn from this guide, and that it helps you avoid these 10 power tool mistakes at all costs. Thank you for joining...and please stay safe out there!
Mistake #1: Blade Guard Sticking
The main safety feature on the circular saw is the blade guard. This semi-circular hub encases the blade, preventing it from coming into contact with anything before and after saw usage.
The bottom half is designed to rotate out of the way as we cut, then snap back into place with the help of a spring. However, damage to the spring or guard hub can cause the blade guard to get stuck in the lifted position.
However, some people attempt to make cuts on the table saw without the rip fence installed. This is a terrible mistake! Our hands cannot create enough stability to allow us to make cuts safely. You may twist the board on accident and bind the blade, which can cause dangerous kickbacks!
Mistake #2: Freehand Table Saw Cutting
The rip fence is an adjustable guide that allows us to make clean, accurate rip cuts on the table saw. By using the rip fence correctly, we can make numerous uniform cuts quickly.
However, some people attempt to make cuts on the table saw without the rip fence installed. This is a terrible mistake!
Our hands cannot create enough stability to allow us to make cuts safely. You may twist the board on accident and bind the blade, which can cause dangerous kickbacks!
Therefore, you should always use the rip fence, stand to the side of the blade, and finish your cuts with a push stick.
Mistake #3: Resting a Tool on Your Body
A very common tendency among both newcomers and pros is allowing a power tool to rest somewhere on their body when the tool is not in use. This is always a bad idea!
It’s too easy to pull a trigger on accident...sometimes our hands do this purely out of reflex. If this happens while the tool is close to your body, you can be badly cut, or your clothes might get pulled into the spindle, or you could eject a nail on accident.
Never allow a tool to rest on your body! Hold it out to the side, or set it on a stable surface when it’s not in use.
Mistake #4: Drill Binding
½” drills are much more powerful than most people think. Both corded and cordless models possess motors strong enough to hurt you with their turning force.
Be sure to keep the tool very well braced, especially when using larger bits. If the bit hangs up from friction, the drill will spin violently for a moment. This unexpected rotation can break your wrist or arm if you’re not ready!
Brace the tool with both hands. And consider using a side handle attachment when using large hole-boring bits, especially with the cordless drill, which has no brake.
Mistake #5: Grinder Wheel Breakage
4-1/2” Angle grinders are strong freehand tools (often around 8 amps). Also, some of the wheels and discs they use are more delicate than they seem.
Cutoff wheels, for instance, are thin “grit discs” made up of fiberglass, resins, and abrasive materials. They’re meant to be used vertically, at a perfect 90° angle. If you put pressure on them at an angle, they can shatter and throw pieces!
Be sure to follow specific usage instructions for every grinder wheel and disc. These will often be printed on the wheel itself, or you can find instructions on manufacturer websites.
Mistake #6: Reaching Over the Table
This is one of the worst mistakes. When you’re cutting things on the table saw...never reach over the blade to retrieve pieces! Also, never pull short pieces from behind the blade.
If tension gets created between the blade and the board, then the piece may get yanked back through the blade. If you’re still holding it, your hand can get drawn into blade as well. Plus, the board may get ejected into your torso!
Never reach over the blade, and never pull short pieces from the back of the saw! Push them through from the front with a push stick (while standing slightly to the side), and let them fall off the back of the saw or land on a lower outfeed surface.
Mistake #7: Putting Hands in the Nailing Path
When nailing components together, people have a tendency to brace the two parts with their free hand very close to the nail gun, often directly in the travel path of the nail. This is a big mistake!
If a nail diverts in the wood, or your line-up is slightly off, then you can easily shoot a nail through your free hand.
Be sure to keep your free hand positioned farther back. And it can often help to angle the gun very slightly. This way, you can avoid a potential skip-out, and the nail will bury itself more deeply in the wood.
Mistake #8: Cutting Short Pieces on the Miter Saw
This is a very dangerous one! Don’t cut pieces shorter than 10” on the miter saw (preferably even 12”). This short length brings your free hand way to close to the blade.
Miter saws can push short pieces into the gap at the back of the fence, causing them to twist a little. This twisting can lead to binding, and binding can cause the blade to kick up violently. This kickback may cause the piece to explode, and your hand might inadvertently come into contact with the blade as you recoil!
Use the miter saw’s hold-down clamp, if you have one. Or, only cut pieces that are closer to 12” long. This will allow you to keep your hand a safe distance from the blade!
Mistake #9: Changing Blades While Plugged In
This one is easy to avoid, and easy to overlook...but you should never change blades while the tool is still plugged in!
Changing blades or bits on many tools requires us to actually grab the blade. If the tool activates while we’re doing this, extremely bad injuries can occur (especially with the table saw and miter saw).
Be sure to unplug the tool, or remove the battery, and keep the power source clearly in sight while you’re changing the blade. Don’t let anyone else come near you or help. When the blade is fully installed, you can plug the tool back in safely.
Mistake #10: Failure to Wear PPE
There’s no getting around it—the easiest way to remain safe is simply to wear your basic safety equipment. A good dust mask, ear plugs or earmuffs, and safety goggles. You should have them on at all times while working with power tools.
It’s just basic common sense. One little speck of material can partially blind you. Screaming tools can permanently damage your hearing. And airborne dust can give you crippling COPD.
Save yourself the trouble. Wear your basic PPE, and work safe for many years to come!
Final Thoughts
That’s our list of the 10 WORST POWER TOOL MISTAKES. I hope the accompanying video wasn’t too scary, and that you aren’t dissuaded from using power tools. If practiced correctly, carpentry is a controlled, calming pastime and profession. We need carpenters now more than ever, and DIYers need the skills to keep tackling their own home projects! So, keep working out there...AND PLEASE STAY SAFE!
Ethan James,
The Honest Carpenter!
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