The Best Belt Sanders of 2022

Buying a Belt Sander

Belt sanders are fantastic tools for smoothing, shaping and grinding away materials such as wood and metal.

They provide far more powerful sanding than you could hope to achieve by hand, and they’re even more powerful than most other types of power sanders. The most common mistake new users make with belt sanders is accidentally removing more material than they intended.

Here’s a quick overview of the different styles of belt sanders, and a list of features to consider when making a purchase.

Handheld or bench-top belt sander

If you’re working on a large piece of material, the sander needs to move, so opt for a handheld model. For something smaller, the sander needs to stay while you maneuver the work material, so your best choice is a bench-top model.

There are other styles of belt sanders with specific specialties, such as curved sanders for pipes, or drum sanders for floors. While those sanders do use a belt, they’re not what most people mean by “belt sander.”

Standard handheld or mini-belt sander

Most handheld belt sanders are two-handed tools with the belt beneath the grip to allow slight downward pressure. Mini-belt sanders (sometimes called file sanders) are handheld models with the belt mounted in front of the grip. These tools are great for sanding surfaces a normal belt sander can’t reach, and they usually have narrower belts — an inch wide or less.

Corded or cordless: Bench-top belt sanders are always corded, with some requiring 220-volt electrical service. Corded handheld units are good for a big project or repetitive work. Handheld cordless sanders let you maneuver around an object with ease. There are a few pneumatic sanders on the market, but we have not included them here.

Length and width: Width and circumference of the belt differentiates belt sanders. A 3 x 21 sander would take a belt 3-in. wide and 21-in. around. Wider belts are better for larger material, while narrow belts are good for detailed projects.

Speed settings: Some belt sanders have only one speed, while others have multiple settings. Handheld models may have trigger-sensitive variable speed.

Flush ends: The design of some belt sanders extends past the edge of the sanding belt, which prevents you from getting to the inside edges of corners. Whether this is an issue depends on your project. If you’re flattening a work bench, it won’t matter.

Dust collection: Belt sanders produce a lot of sawdust. They all attempt some dust control, but none are 100 percent effective. Ideally, look for a belt sander with a dust collection port that connects to a shop vacuum or dust extraction system. Even then, plan on spending some time sweeping up after you use it.

Cost: Entry-level handheld sanders are likely to run around $100, but you’ll get much more performance for your investment if you step up to $250 or so. A splurge handheld might run up to $400. Bench-top models range from $100 for entry-level models and up to $800 for a high-quality unit. Splurge bench-top sanders can run into the thousands.

Brushed or brushless Motor: Brushed electric motors are more affordable, but brushless motors last longer and generate less heat.

Additional features: These include trigger locks, pressure indicators and easy belt removal. None are essential to the operation of a belt sander, but they’re always nice to have.

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