“Belt sander” covers several quite different machines. Some you hold and move over the work; others stand on the bench and you bring the work to them. Before comparing brands, decide which kind suits the work you do, then check one thing most buyers forget: which belt it takes, and whether you can buy that belt easily.
Which kind?
- Handheld belt sander. For flattening and stripping large surfaces: tabletops, doors, floors, decking, old paint. You move the sander; the work stays put. See belts for handheld belt sanders.
- Bench belt sander or belt and disc sander. For shaping, squaring and smoothing small and medium parts: ends of boards, curves, small components. You bring the work to the machine and rest it on a table. See belts for belt and disc sanders.
- Belt file. For tight spaces, slots, edges and deburring. See belts for belt files.
- Belt grinder. For metal and knife making: fast belts, contact wheels, sparks. See belts for belt grinders.
- Edge sander. For truing long edges and faces in a woodworking shop with space for it. See belts for edge sanders.
Check the belt before you buy.
A sander is only useful while you can get belts for it. Common sizes such as 3 × 21 in, 75 × 533 mm, 4 × 36 in or 6 × 48 in are sold almost everywhere, in every grit. An unusual size may only come from the manufacturer, in a few grits, at a higher price. Look the model up on BenchRefill before you buy: the machine page shows the documented belt size, and the size page shows how many other machines share it.
Handheld sanders: what to compare.
- Belt width. A 75 mm (3 in) belt is the all-rounder. A 100 mm (4 in) machine removes material faster over large areas but is heavier.
- Weight and balance. A heavier sander does more of the work for you on flat surfaces; a lighter one is easier on vertical and overhead work.
- Speed control. Variable speed helps with paint, plastics and fine finishing.
- Dust collection. A bag fills fast; a port for a vacuum or extractor makes a big difference. See dust extraction.
- Tracking and belt change. An easy tension lever and a tracking knob you can reach while holding the sander save time.
Bench sanders: what to compare.
- Belt size and table. A wider belt and a solid, tilting table give more support for squaring and angles.
- Belt position. Many machines let the belt arm tilt between horizontal and vertical.
- Disc size, on a belt and disc sander, and whether its discs are self-adhesive or hook-and-loop.
- Mass and stability. A heavy machine, bolted down, vibrates less and gives a better surface.