5" vs. 6" ROS advice

[Patrick Varley]

Looking for some insight as I try to upgrade my sander game. Read through some old threads, but just wanted to see current thoughts.

I currently use a Bosch 5" ROS for most of my work. I'm just a hobbyist, so not doing anything for production. Mostly smaller projects, but occasionally some small cabinets or tables.

I've been thinking about getting one of the Bosch dual-mode sanders (GET75N) in either the 5" or 6" version. The aggressive mode would be useful sometimes to hog of material for some of the things that I do. I'd consider one of the Festools (ETS 125 vs. 150), but a bit out of my price range.

My main question is whether the 5" vs. 6" really makes a difference. Obviously it could speed things up, but given I'm not high throughout and not doing large pieces regularly, thinking the benefit may be minimal. It would also mean stocking another range of 6" sanding discs. Instant gratification also getting the best of me, as the 6" is on 2 month wait from Amazon (where I have existing gift cards).I'd also be open to hear other better options to consider.

[andrew whicker]

I have that Bosch model... a few years older model.

Sometimes, I think it's too powerful personally. Likes to get away from me if I'm not paying really close attention. I've said this before, but I've used a pneumatic paddle sander at another shop (Mirka) and it was a dream. Much preferred.

[Tom M King]

I also have that 6" Bosch. It's a beast, and I call what they call Turbo Mode, BEAST MODE. You need to be ready to go to work using it with 80 grit in Beast Mode. 5" ones don't get used much any more.

[Jim Becker]

My "round" sanders are both 150mm (6") and I can only think of a very few number of times I would have preferred a 125mm/5" format over the years.

One caution about the dual-mode sanders, regardless of brand...they really prefer to be used two handed in many situations which can be uncomfortable. I rarely pull out my Rotex for that reason...only when I really need that extra removal capability that rotary mode brings. Otherwise, it's ROS all the way with the 150/3.

BTW, one specific version of the 125mm Festool can also take a 150mm pad, meaning it can be used with both sizes of abrasive media, depending on one's needs. That could be a good option for someone that really wants/needs both. I forget the specific model at the moment, but it's been mentioned previously, both here and in the Festool owner's group discussions.

[John TenEyck]

I use a Bosch ROS65VC, not a dual mode machine. I have both the 6" and 5" pads for it. I use the 6" pad 95% of the time because it works faster and feels more stable, but some sanding media only are available in 5" format, ergo both pads. I would look to see if both 5 and 6" pads are available for the sander you are considering. If so, you can change as needed.

John

[Jack Lilley]

I use a 5" Mirka and I love it. It's a pneumatic model with dust collection and the thing does a great job. I do have a 6" RO in the shop but find I only use it on larger projects because of the size and weight. I primarily build cabinets and find the 5" gets in about any spot and causes less fatigue if finish sanding a stack of doors or drawers.

[George Bokros]

If you are going to keep and use the 5 inch standardize on one size disk, lower investment in sandpaper.

[Stan Calow]

It was probably said in earlier threads you may have seen. What are you making? Large flat surfaces like table tops? Yeah a 6" is good. Smaller pieces with edges and a variety of surfaces - 5". Most of my use is on smaller stuff, and my 6" ROS requires two hands for steady operations, whereas I can maneuver a 5" one-handed while manipulating the workpiece.

[Jim Dwight]

I use and like my Bosch devs1250 - an earlier version of the sander you are looking at. Mine has a 6 inch pad. I recently got a Milwaukee 5 inch battery operated sander for when I do not need the rapid removal of the Bosch. Most of the time I want the Bosch - I want to minimize my time sanding. I have mostly 6 inch sanding discs, I keep a few for the Milwaukee. I use my Bosch one handed but it is a hand full. I have used it this way with 40 grit paper in turbo mode but it is not really comfortable. But with finer paper (150 or finer) it is not bad. You have to be careful especially one handed with the speed of removal on the side with the motor. The greater weight makes it take off material quicker on that side. When you have two hands on it, it is easier to keep it flat to the work so removal is more consistent. I don't really use my 3x21 belt sander any more, the Bosch removes material about as fast.

I wear extra large gloves, it may help with one handed use of this admittedly large sander. I almost never use the speed control but it has it and it might help if you find it getting away from you.

[Kris Cook]

I just drank the Kool-Aid and bought the Festool 5" ETS EC 125/3 sander. I went with the 5" over the 6" because I thought it would be easier to handle.

[roger wiegand]

I loved my Bosch 1250 DEVS right up until it died with no replacement parts available. It was ny only sander for a long time (well, not counting the PC330 that I keep around for old times sake) Current sanders are a 6" Mirka Deros (5mm orbit) and Festool ETS EC150/3 and a Grex pneumatic with a 2" pad. I use the Deros 90% of the time, the Festool is mostly a backup and way to quickly alternate between grits for certain tasks. I've never felt any need or desire for a 5" sander-- too small for big jobs, too big for small jobs. I'd love to have an electric RO sander about the size of the Grex with 1 to 3" disks for both small pieces and turnings-- the alternative being several kilobucks for a bigger compressor.

[Jim Dwight]

I will also add that the size of the pad is only one factor. The "turbo" mode of the Bosch is very important to me as is the larger orbit. I have a 6 inch DeWalt in the "almost never use" drawer because it sands so slowly. No turbo and small orbit. I would take a 5 inch with the larger orbit and turbo mode any day over a plain little orbit 6 inch sander.

[Matt Day]

I’m in the market for a dual mode sander and it will likely be a Bosch 6”. Half the price of the Festool and by all accounts the same or better performance.

[Paul Haus]

I have 4 ROS sanders, 2 electric and 2 pneumatic. All now are 5" as I replaced the pad on one from 6" to 5". Other than the suction holes in the pads, they're hook and loop and work well.
I'd say if you standardize on one size, so much the better.

[Patrick Varley]

Thanks everyone.

On the question of projects, as I mentioned, it's only occasionally large pieces/panels. But I was wondering if I'd miss the larger sander on those few occasions.

I do think having the option for more aggressive removal is important. With the feedback on 6" may just go that route and standardize on 6" with a smaller detail sander as well. While I'd love a 3" pneumatic, it would also require a new compressor (for which I have neither the space or money).

[Rich Engelhardt]

I picked up a Ridgid 6" a few years back to scuff sand the hardwood floors of a rental house.
They were in decent shape and didn't need sanded all the way down to bare wood.

I've since used it on smaller tasks.

The other sander I have is a DeWalt 5" single speed. I like to use the 5" because it's nimbler and doesn't seem to add that much time. The DeWalt is near its end of life however and I'm looking at what I can replace it with.

[John Kananis]

Patrick, for the type of work you mention (small cabinets, tables and smaller protects), I'd invest in a decent hand plane and a card scraper. Nicer finish, less work, no dust, no electrons and no sandpaper to buy.

[Prashun Patel]

You sound like me in terms of project types. I have never missed a larger sander. I have a 5”. If anything, there are way more times I need a smaller sander for concave parts like bowls .

If you have to hog off a ton of material with a sander I would suggest there are more efficient methods such as planes, a planer or even a belt sander (for say cutting boards).

The biggest bang for buck on sanding efficiency is not pad size but paper quality and changing it often. At least for me.

[Mike Henderson]

I'm the same. I bought a 6" sander but almost always use my 5" sanders. They better fit the work I do.

Mike

[Mike Hollingsworth]

I keep well stocked with all the fine grits for my 5" Rotex. I polish rosewoods to 15000 with Micro Mesh.
I keep course stuff for the 6".

[james manutes]

Another "I've" got both here . There are situations where one is preferred over the other , so the flexibility is great . I'll admit that ordering 2 sizes of paper is a bummer , but - oh well .

[Patrick Varley]

Again, thanks for all the input. Decided to go with a 6" knowing that I'd keep a 5" around for some things.

Probably not a popular option here, but I'm a gambling man and took a flyer on a 6" Deros clone. I had seen Peter Millard review one and seemed like it was worth a shot (https://youtu.be/jelEm54OLQw). I have to say that on initial unboxing and initial testing, I was surprised (in a good way) on the build quality and performance. Ultimately I know the real issue might be longevity but I picked up an extended warranty. Worst case, the thing dies after a year and I end up with a gift card for something else (after using this thing, I'd probably consider biting the bullet and just getting the Deros).