Belt sanders remove material fast. That’s both their strength and their danger – it’s easy to dig in and ruin a surface. Here’s what I’ve learned using them over the years.
Types
Handheld belt sanders are for big surfaces – tabletops, floors, large panels. You move the tool across the work. Benchtop belt sanders stay put while you bring the work to them – better for smaller pieces and precision work.
Common belt sizes: 3×18″, 3×21″, and 4×24″. The first number is width, second is length. Bigger removes more material faster but is harder to control in tight spaces.
What I Use
My main sander is a DeWalt 3×21″. Powerful enough for most tasks, small enough to maneuver. Variable speed is essential – you want slower speeds for delicate work, faster for aggressive stock removal.
For rough work on large surfaces, a 4×24″ makes sense. For precision work on smaller pieces, a stationary belt/disc combo gives better control.
Using a Handheld Belt Sander
Start it off the work surface, then lower onto the wood. Never start it resting on the wood – it’ll gouge immediately.
Keep it moving. Dwelling in one spot digs a trough. Steady, even passes with light pressure. Let the weight of the tool do the work.
Work with the grain. Cross-grain sanding leaves scratches that show through finish.
Grit Selection
Start with 80 grit for serious removal – old finish, rough lumber. Move to 120 for shaping, then 150 for smoothing. Stop at 180 before switching to a random orbit sander for final smoothing.
Jumping grits too fast leaves scratches from the previous grit. The pattern is: each grit removes scratches from the previous grit.
Dust Collection
Belt sanders produce tons of dust. Use a sander with a good dust bag, or connect to a shop vac. Your lungs will thank you.
Common Mistakes
Pressing too hard wears out belts fast and can burn the wood. Angling the sander gouges edges. Not tracking the belt properly causes it to wander off the rollers. Check belt tension and tracking before each use.
