Power Tool Buying Guide for Sanders

What Is a Sander?

A sander is a power device designed to smooth, level, or strip surfaces, usually wood, metal, or paint. Whether you're prepping a tabletop for stain, knocking down a rough edge, or stripping old finish, a sander saves time and effort. It replaces hours of hand sanding with consistent speed, pressure, and finish quality. There are several types of sanders, each with its own specialty depending on the job.

History of the Sander

The earliest versions of power sanders showed up in the 1920s, starting with drum and belt-driven machines. Porter-Cable made a big leap in the 1950s with the introduction of the random orbit sander—a design that revolutionized sanding by combining consistent abrasion with swirl-free finishes. Since then, companies like Makita, Bosch, and Festool have refined motor designs, dust collection, and pad systems to improve control and performance on everything from rough stock to fine furniture.

What It’s Used For

Sanders are used in nearly every woodworking and finishing trade. Typical uses include:

  • Smoothing rough lumber or edges
  • Stripping old finishes or paint
  • Leveling joints or repairs
  • Prepping surfaces for stain or paint
  • Removing rust or corrosion on metal
  • Refinishing furniture or cabinets

What to Look for When Buying

Type of Sander

  • Random Orbit: Most versatile, great for finish sanding with minimal swirl marks
  • Sheet (Palm) Sander: Ideal for light sanding or smoothing between coats
  • Belt Sander: Aggressive—good for fast material removal on flat surfaces
  • Detail Sander: Small, pointed pad for tight spaces and corners
  • Oscillating Spindle Sander: Used on curves or inside contours (usually bench-mounted)

Dust Collection

  • Look for built-in dust bags or vacuum ports
  • Good dust control keeps surfaces cleaner and extends pad life

Speed Control

  • Variable speed gives more control for different materials and finishes
  • Higher speeds for fast removal, lower for delicate work

Pad Size and Shape

  • Round pads for orbitals, square pads for sheet sanders
  • Larger pads cover more area; smaller ones give better control in tight spots

Ergonomics and Vibration

  • Lightweight design and rubber grips make a big difference during longer jobs
  • Anti-vibration systems reduce fatigue and hand numbness

Paper Attachment

  • Hook and loop (Velcro-style) is fastest
  • Clamp-style is more common on older sheet sanders

Pros and Cons

Pros

  • Major time saver for prep and finishing
  • Provides smoother, more even results than hand sanding
  • Available in styles for every need, from aggressive removal to fine detail
  • Many options include dust collection

Cons

  • Creates fine dust that requires cleanup or collection
  • Some models vibrate heavily over long periods
  • Not ideal for sculpted or contoured work without a specialty pad
  • Requires the right grit selection to avoid gouging or swirl marks

Grit Selection Basics

  • 60–80 grit: Heavy stock removal, stripping paint or stain
  • 100–120 grit: General sanding, smoothing edges
  • 150–180 grit: Pre-finishing work, sanding between coats
  • 220+ grit: Final finish prep, especially for stains or clear coats

Always start with the coarsest grit needed, then step up through finer grits. Skipping grits can leave deep scratches that show up after finishing.

Safety and Maintenance Tips

  • Always wear a dust mask or use a vacuum hookup
  • Let the sander’s weight do the work, don’t press too hard
  • Change pads or paper regularly to avoid burning the surface
  • Check cords and dust bags for wear
  • Clean vents and filters to prevent overheating
  • Store in a dry place to avoid rust on pad plates

Who This Is For

  • Homeowners refinishing cabinets, furniture, or prepping paint
  • DIYers working on home improvements or woodworking
  • Pros in carpentry, finishing, cabinetry, and auto body repair

If you’re building or restoring anything that gets painted, stained, or smoothed, a sander is a must-have.

FAQ

Can I use one sander for everything?

A random orbit sander covers 80% of general sanding tasks. For heavy stripping or tight corners, you’ll need a belt or detail sander.

What’s the difference between orbital and sheet sanders?

Random orbitals have a spinning, circular pad and leave fewer marks. Sheet sanders move in tiny square patterns and are better for corners.

Why is my sander leaving swirl marks?

Dull paper, too much pressure, or skipping grits can all cause swirls. Let the tool do the work and keep fresh paper on it.

Final Thoughts

A good sander does more than just smooth, it saves time, effort, and frustration. Whether you’re leveling out a glued panel, prepping for stain, or removing old paint, the right sander can deliver clean, professional results. Know the job, match the type, and choose the right grit. When used right, a sander is one of the most underrated yet essential items in your workshop.