Cordless Random-Orbit Sanders

This review evaluates seven 6-inch random-orbit sanders, chosen for their stroke models ranging from 2mm to 3mm and prices between $100 and over $650. The tools are categorized into 'low profile' and 'tall profile' designs. The primary objective of the testing was to identify sanders that provide a consistently high-quality finish and are comfortable for extended use, addressing the needs of cabinetmakers and other woodworking professionals. Initial testing involved providing the sanders to multiple professional woodworkers for real-world application over several months, gathering their practical feedback. Further assessment included sanding plexiglass panels to analyze scratch patterns and conducting controlled tests to measure material removal/collection and overall sanding results. To ensure consistency, the same brand of sandpaper with a matching hole pattern was used for each sander. All tools were operated at their highest speed and connected to a quality dust extractor set at medium power. While most sanders produced satisfactory scratch patterns and decent dust collection, a key finding was the ergonomic disadvantage of 'tall profile' sanders, particularly for one-handed operation. These heavier, bulkier tools were found to be more challenging to manage, leading to increased fatigue during prolonged use or when working in awkward positions. The 'low profile' sanders, conversely, offered significant ergonomic benefits. They were lighter, more comfortable for one-handed sanding, and better suited for delicate work, overhead tasks, and large surfaces like tabletops or stair treads where reduced fatigue is crucial. Although generally more expensive, their enhanced usability and precision were highlighted as key advantages. The Mirka DEROS 625X CV emerged as the top performer, being praised for its ease of use, ability to minimize fatigue, and exceptional finish quality. Its lightweight, low-profile design, DC brushless motor, and palm-activated paddle switch were noted as superior features, contributing to its effectiveness for both detailed and general sanding tasks. The Festool ETS EC, another low-profile model, was identified as a close second. Among the 'tall profile' sanders, the Festool ETS 150 stood out as the most comfortable for one-handed use due to its lighter weight and smaller grip, despite its higher price point compared to other tall models. Other sanders reviewed included the Makita BO6030, Bosch GEX34-6, Ridgid R2611, and Metabo SXE 450 TurboTec. The Makita BO6030 demonstrated the worst performance in terms of finish quality, producing noticeable swirl inconsistencies, and had the smallest dust port. The Bosch GEX34-6, while having a high material removal rate, was criticized for its large size and uncomfortable grip, making it tiring for extended use. The Ridgid R2611, the heaviest sander tested, suffered from poor balance and dust collection, tending to rock or wobble during operation. The Metabo SXE 450 TurboTec offered an adjustable stroke size and a unique turbo mode, but its effectiveness in changing oscillation modes was not clearly discernible. The testing methodology for scratch patterns involved sanding plexiglass with different grits, while material removal was measured by weighing wood blanks before and after sanding for 30 minutes, followed by staining to reveal scratch patterns. The author, Stefan Straka, a cabinetmaker, emphasized that sanding speed is less critical than achieving a high-quality finish and maintaining comfort during long sanding sessions. #RandomOrbitSanders #PowerTools #WoodworkingTools #SanderReview #ToolTesting #Cabinetmaking #FinishCarpentry #Ergonomics #DustCollection

This article presents a comprehensive review and test of various cordless planers available in the market, focusing on their utility in woodworking and carpentry tasks. The author, a professional carpenter, highlights the advantages of cordless power planers over traditional hand planes, particularly their quick and effortless stock removal and the ease of replacing disposable blades, which minimizes downtime due to blade damage from job site hazards. The tested models include offerings from Bosch, Makita, DeWalt, Metabo HPT, Ryobi, and Milwaukee. All standard models evaluated share common features such as 3 1⁄4-inch-wide disposable carbide blades, bevel grooves for easing edges, and small kickstands to protect the cutter head. Additionally, two smaller cordless models from Bosch and Milwaukee, designed for finish carpentry, were also included in the evaluation. The article specifies that all listed model numbers and prices correspond to the tool-only versions, though some manufacturers provide kits that include batteries and chargers. The versatility of these power planers is emphasized, ranging from precise tasks like fitting inset cabinet doors to heavy-duty applications such as significant stock removal, straightening bowed framing, and flattening wide hardwood slabs. They are also suitable for common finish-carpentry jobs, including trimming full-size doors, shaving extension jambs, and planing to scribed lines for tight-fitting built-ins and cabinets on irregular walls. The performance evaluation considered this broad spectrum of applications. Blade characteristics are discussed, noting that all planers utilize double-edged carbide blades that perform well across various wood types. Blade changes are simplified by reversing the blades to expose a new edge. Bosch planers are noted for their unique counterbalanced cutter heads that accommodate a single blade, streamlining blade changes and ensuring alignment. For working with older stock that might contain embedded nails, DeWalt, Metabo HPT, and Makita offer more economical, resharpenable high-speed steel blades as an alternative to carbide. Key features for a superior tool are identified, including the ability to eject chips from both sides for user convenience and clear visibility. While Metabo HPT, Makita, and DeWalt models only offer right-side chip ejection, others, including the smaller planers, allow for selection between right and left. Ryobi is commended for including a dust bag with its planer, a feature often missing in other larger models. Fences, crucial for straight and square-edged passes, are generally included with larger planers, with Makita being an exception requiring separate purchase. The Milwaukee’s fence is highlighted as superior due to its size and bevel-cutting capability. The fences on Metabo HPT and Ryobi are noted as being smaller but can be improved with an auxiliary wooden fence. For raw power in surfacing rough hardwood, the Makita and Metabo HPT models with brushed motors are recommended. The Milwaukee and Bosch planers are praised for general carpentry and finish work, offering a balance of construction quality, user-friendly blade changes, and adaptability for both heavy and precise tasks. The Milwaukee is slightly preferred for its adjustable bevel fence and convenient chip ejection lever. The smaller 12V planers from Milwaukee and Bosch are recognized as valuable additions for trim carpenters, ideal for one-handed operation in confined spaces, precise work on moldings and cabinet boxes, and tapering narrow stock for doors and windows. The testing methodology involved evaluating performance on end and edge grain, various hard and softwoods (fir, oak, walnut, veneer plywood), and the quality of rabbet cuts. All planers performed effectively on different wood types when using fresh blades and appropriate feed rates. The ability to create rabbets is consistent across all models due to the blade extension across the sole. Specific recommendations for each tested planer highlight their unique strengths, such as the Milwaukee’s large bevel-adjustable fence, the Ryobi’s value, the Bosch’s innovative single-blade system and safety features, the DeWalt’s ruggedness and onboard blade storage, the Makita’s powerful smooth cuts, the Metabo HPT’s power and included fence, and the smaller Milwaukee and Bosch models’ suitability for fine finish work and dust control. The article concludes by listing the author and photographers involved in the product review. #CordlessPlaners #PowerTools #ToolTest #Woodworking #FinishCarpentry #HomeImprovement #CarpentryTools #BladeChange #DustCollection

This article details the construction and evolution of Mark Rehorst's Arrakis 3.0 sand table, a robotic sand table inspired by Japanese Zen gardens and the fictional planet Arrakis from 'Dune.' The device creates intricate patterns in sand using a rolling metal ball, propelled by a powerful neodymium magnet hidden beneath the tabletop. This magnetic movement is controlled by a CoreXY motion system, which borrows heavily from modern 3D printer technology, utilizing G6 belts, a Duet3D mainboard, NEMA 17 steppers, and 3D-printed components to assemble its aluminum extrusions. This design allows for high-speed operation, with the ball capable of moving at 2000 mm/s, although Rehorst typically opts for slower speeds, around 1000 mm/s for general movement and 200 mm/s for detailed pattern drawing to prevent sand displacement. The Arrakis 3.0 represents a significant iteration in Rehorst's sand table projects, designed with improved construction and portability in mind. Measuring 2 feet by 4 feet (approximately 61 cm by 122 cm), the table is sized to easily fit through doors and accommodate an off-the-shelf coffee table glass slab, a practical consideration stemming from lessons learned in previous versions. This iterative design process highlights the benefits of learning from past projects, with the current model showing clear advancements from a 2020 version. While CoreXY is a popular choice for such projects due to its efficiency, the article also notes the existence of alternative motion systems in other sand tables, such as polar mechanisms and SCARA arms, demonstrating the diverse engineering approaches possible. A key innovation in the Arrakis 3.0 is the integration of iHSV servomotors instead of traditional stepper motors. These servomotors, which are NEMA 17 steppers with built-in drivers and 1000-line optical encoders, operate in a closed-loop system. From the perspective of the Duet controller, they function like standard steppers, accepting step, direction, and enable signals. However, their ability to rotate at 3000 RPM with consistent torque allows the magnetic ball to achieve much higher speeds—up to 2000 mm/s—compared to the 500 mm/s limit of older NEMA 23 steppers. This technological upgrade also contributes to a quieter operation, as the servomotors handle higher speeds without the significant noise associated with conventional steppers. The patterns drawn by the table are generated using Sandify software, with a custom Perl post-processor developed by Rehorst to assign dual speeds for different parts of the pattern, optimizing both the efficiency of movement and the precision of the sand drawings. #Robotics #SandTable #CoreXY #Duet3D #3DPrinting #ZenGarden #Servomotors #HomeDecor #DIYProjects