This Tool Test includes three drywall sanders ranging in price from $500 to $2200, and compares their dust-collection efficiency with their accompanying vacuums, their finish quality, and their ease of use. It highlights the differences between rotary sanders and random-orbit sanders, with random-orbit sanders providing a smoother finish.

While rotary sanders are effective for tasks like removing texture or smoothing poorly finished drywall, they may require additional steps for a professional-quality surface. The article concludes that for remodeling projects in occupied homes, investing in a high-end sander with dust-extraction capabilities can improve productivity, client satisfaction, and overall results. Click here to watch a video of each sander in action.

A Good Drywall Sander Makes a Difference

It’s fair to say that most construction projects involve drywall and the coating and sanding of joint compound on seams, corners, and fasteners. Although sanding drywall isn’t difficult, especially for professional finishers who have to sand very little, any amount of sanding produces dust.

The fine dust created from sanding joint compound is the primary complaint of homeowners who have gone through remodeling projects. And drywall dust isn’t just a headache for clients—it’s a problem for contractors too. Controlling dust to keep clients happy is time-­consuming and not always totally effective, which can be costly. A whole-house cleaning to satisfy a client angry about drywall dust could easily eat up the profit on a small job.

A modern drywall sander connected to a tool-triggered vacuum goes a long way to controlling dust. It can also help nonprofessional drywallers get a professional-quality finish—and it can help anyone with the heinous task of removing painted textures from ceilings and walls. The secret to a drywall sander’s dust management is a shrouded sanding disk plus HEPA filters and a filter bag on a dust-extractor vacuum.

You might think a drywall sander costing hundreds of dollars at minimum is overkill. That might be true for new builds where there’s no client, or for experienced drywall finishers. However, for remodeling work, texture removal, and larger drywall projects finished by those with less experience, a drywall sander is a huge help, both for collecting dust and for eliminating excess compound from seams and corners.

We recently tested three drywall sanders with their compatible dust extractors, ranging in price from about $500 to $2200. What follows is an explanation of what you get for an entry-level, middle-grade, and high-end drywall sanding system. The price range reflects differences in dust collection, ease of achieving a smooth surface, and comfort during long periods of sanding.

We’ve heard folks who have never used a drywall sander remark that the tool is too aggressive for sanding a pro-quality finish, but all of these sanders have variable-speed motors that allow you to slow the sanding action to match the skill of the finisher. Paper for the sanders is widely available in grits from 60 to 320 to match virtually any drywall-smoothing task.

Two Kinds of Sanding

The biggest difference among sanders is the pattern in which they sand. Much like the first commercially available drywall sander in the United States, the Porter-Cable 7800, the lower- and mid-priced Bauer and Bosch sanders have a rotating sanding disk, like a handheld grinder.

The Festool and other high-end sanders pioneered in Europe have a random-orbit sanding action, like a woodworking sander. A random-orbit sander provides a smoother surface than a rotating disk, which tends to create ridges when the sanding head is rocking, even slightly. The constantly varying random-orbit motion is flatter and produces a smoother surface.

All of the sanders use 9-in. hook-and-loop sanding disks. Surprisingly, although the disks have different hole patterns, they’re interchangeable. We found only a small reduction in dust-collection efficiency when using the Bauer disks on the other sanders, even though they have fewer holes than the Bosch sanding screens (which are mostly holes) and the Festool disks (which have additional perimeter holes). The Bauer sander demonstrated the same dust-collection efficiency with the Bosch and Festool sanding media as it did with its own brand. So any 9-in. drywall sanding disk will work on any sander in a pinch.

Common Features

All of the sanders have adjustable housings for tall walls and 9-ft. or 10-ft. ceilings. They can also be made sufficiently compact for closets and wall patches. Bauer’s simple telescopic extension slips into the end of the tool housing at the vacuum connection, adding another 18 in. of reach.

Bosch and Festool use one or two extension tubes to lengthen the center of the tool, providing better balance when they’re extended. Those who have never tried a drywall sander often believe that they must be heavy when used overhead. In actuality, the suction from the dust extractor helps hold the sanding head to walls and ceilings for more efficient sanding and less strain, a feature we refer to as “suction assist.”

The Verdict

After using these tools head-to-head on identical test sections (see “How we tested,” p. 31), we agree that for sanding painted texture or gobs of joint compound, any drywall sander is better than none—but for drywall finishing on mainstream and upper-end projects, you’ll want the better finish quality of a random-orbit drywall sander like Festool’s Planex.

Rotary drywall sanders are great for removing texture and smoothing badly finished drywall, and they would likely be a game-changer for smoothing the work of amateur finishers. But our testing showed that the rotary sanders did not produce as smooth a finish as the random-orbit drywall sander and would likely require further finishing steps like a skim coat of compound or a drywall surfacing primer for the kind of smooth surface expected of professional finishing. In many cases even the Festool requires similar finishing steps, especially when glossy paints are specified or when the space has raking sunlight or another form of bright, focused light.

With the understanding that a random-orbit sander is preferred for drywall comes the obvious question: Is a drywall-sander setup that costs more than $2000 worth the investment? If you’re a pro and your remodeling clients are OK with dust, or if you routinely use subcontractors for drywall work in unoccupied houses, probably not. But if your remodeling work is for clients living in the house, it’s absolutely worth it. This is especially true of small projects when emptying and enclosing the space is often impractical.

The cost of the sander and dust extractor could be spread over a few projects and paid for with increased productivity and greater customer satisfaction. Your sander and vacuum might help you get work from well-paying clients looking for less disruption during their remodeling projects—and if you sometimes do your own finishing out of choice or necessity, the sander setup can help you get professional-looking results with almost no mess.

We also think there’s a strong case for enthusiast DIYers to spring for the Planex. Both of us have used it for home projects small and large. In all cases, it makes sanding drywall less taxing and less messy, and in all but the most challenging conditions—like glossy paint or raking light—it leaves a smooth surface that’s ready for primer. It might even make sense to buy one for a single large project and then resell it when the work is done.

How We Tested

To test the sanders head-to-head, we sanded sections of painted texture, strips of all-­purpose compound, sections of inside corner, and simulated patches from about 2 in. to about 3 ft. square. A tool-triggered dust-collecting vacuum is key to each sander’s dust management and quality of finish, so we connected the matching vacs equipped with the recommended filters and filter bags.

A primary advantage of these drywall sanders is dust collection, so we evaluated the effectiveness of dust collection during all of these tests. We also evaluated the ability to remove texture, the quality of the finish, and the comfort of use.

Bauer 21105E-Bv Drywall Sander

Minimum length 45 in. • Maximum length 65.25 in. • Weight at maximum length 9.4 lb. • dB Level 85.5 • Price $170

Harbor Freight’s Bauer drywall sander removes painted texture and produces reasonably smooth seams, corners, and patches. Compared to the other sanders, it has more vibration, an awkward switch arrangement, and a flimsy extension tube and hose connection. It also has a greater tendency for surface chatter and doesn’t reach as far into inside corners as the two other sanders we tested.

On the plus side, it is far less expensive than other options. Using fine paper and a slower motor speed helps control chatter, and you can produce decent drywall surfaces with less mess and effort than with hand-sanding. The onboard LEDs provide raking light, illuminating areas that need more sanding.

The sander’s vibration makes it tiring to use. The finish it leaves may be fine for some projects, but additional hand-sanding, a skim coat of compound, or surfacing primer likely will be required. Still, faced with painted texture or amateur-finished drywall, we’d buy the Bauer sander in a heartbeat. Even for a single project, it makes the work go faster with less mess than hand-sanding.

Hercules HE028 Dust Extractor

Capacity 12 gal. • Cord length 24 ft. • Weight 37 lb. • dB Level* 75 • Price $350

Harbor Freight’s Hercules is a reasonably priced and effective dust extractor sold with a 15-ft. hose and common attachments. The construction is rugged and the wheels are big enough to roll over small obstacles. Like all the vacs in the test, it includes automatic filter cleaning, but unlike the others, its cleaning cycle causes reduced suction for a second or two every 10 to 20 seconds.

It’s not as noticeable when sanding drywall, as the sander’s shroud contains the dust for the filter-cleaning periods, but the filter clean is evident when you’re using the extractor like a shop vac. If you don’t pause during the filter clean, you may have to take a second pass with the cleaning tool to get all of the dirt. Because the Hercules hose and fittings are of a nonstandard size, additional tools and replacements must come from Harbor Freight.

^{*Decibel levels measured 3 ft. from tool motor}

BOSCH GTR 55-85 Drywall Sander

Minimum length 45 in. • Maximum length 90.55 in. • Weight at maximum length 12.2 lb. • dB Level 83.5 • Price $500

Bosch’s sander is well balanced, with handles arranged for comfortable positioning. The sanding head’s angle makes it easy to land the disk evenly on the wall for a smooth start to sanding. The motor and sanding head operate quietly, with little vibration through the handles. These features make the Bosch a more comfortable choice than the Bauer for long hours of sanding.

Like the other sanders, the Bosch has adjustable suction and sanding speed. A locking connection on the sander matches the Bosch dust-extractor hose and prevents it from coming loose when extended, and an included adapter allows the sander to connect to vacs from other manufacturers.

The Bosch is good at removing painted texture; its aggressive sanding quickly removes material and leaves little dust remaining. The dust shroud on the Bosch is the only one with a removable front section for getting all the way into corners. The sander length can be extended with up to two 23-in. sections of tubing that lock together to reach a roughly 10-ft. ceiling. In addition to Bosch’s mesh-based sanding screens, we tried this sander with Festool’s and Bauer’s solid sanding disks because the screens proved difficult to source.

It was hard to tell a difference in sanding speed, surface quality, or dust collection between the three sanding media. The biggest downside to this smooth-running machine is the rotary sanding action, which, as with the Bauer, leaves a rougher surface than the random-orbit sanding pattern found on the Festool.

BOSCH VAC090AH Dust Extractor

Capacity 9 gal. • Cord length 13.5 ft. • Weight 38 lb. • dB Level 73 • Price $550

The Bosch dust extractor has intuitive controls, and you can dial back the motor speed when you’re using it for dust extraction with a high-draw tool on a 15-amp circuit to keep the circuit from overloading. The rectangular pleated filter is in a compartment separate from the main collection bin and uses mechanical “thumping” to clean the filter.

The system is loud, but it doesn’t produce a temporary loss of suction like the Bauer. The only real annoyance with the Bosch vac is the ridiculously small swivel castors on the front of the machine. And the front wheel’s lever-type brake is poorly positioned, making it easy to activate accidentally with your toe.

Festool Planex LHS2 Drywall Sander

Minimum length 48 in. • Maximum length 84 in. • Weight at maximum length 12.7 lb. • dB Level 74 • Price $1300

The Planex LHS2’s balanced housing, precise controls, quiet motor, and intelligent design come together to make sanding drywall almost enjoyable. Its orbital action produces a smooth, flat surface that’s ready for primer and paint in many cases. The surface quality is good enough that Noah uses it to smooth the stippled surface, sags, and ridges left on previously painted surfaces when the painter applied too much paint at once.

As with the Bosch, the Festool’s housing can be lengthened with 20-in. tube sections to match wall or ceiling height. The LED light has no bright or dark spots and highlights even small imperfections. Adjustable suction and sanding speed allow you to fine-tune the suction assist so the sander moves easily over the substrate, even when sanding gnarly textures.

The big downside to this tool is the price, but it leaves the smoothest surface with typical drywall finishing and quickly removes painted texture and thick compound. Using it for hours involves little strain and makes drywall sanding nearly dust-free. If you’re not a pro finisher and are looking for the smoothest walls and ceiling, or if you’re a pro looking for the cleanest, most enjoyable way to sand drywall, this is the drywall sander to get.

Festool CT36 Dust Extractor

Capacity 9.5 gal. • Cord length 25 ft. • Weight 32 lb. • dB Level 74.5 • Price $865

Paying nearly $900 for what many would describe as a shop vac can be a tough pill to swallow, but the Festool CT36 works great. When you consider that a dust extractor is put to regular use for other painting, carpentry, and remodeling tasks and cleanup, the price becomes less of an obstacle. Commonsense features abound.

The Planex comes with its own high-flex hose that connects the vac securely to the sander. The filter bag attaches to the inlet with a lock tab that ensures the connection is tight. The motor-speed control prevents blown breakers and reduces suction when maximum power makes the sander stick to the surface.

The angled controls are easy to reach and see. You can adjust the filter cleaning to match the amount of dust produced. The wheels are big and roll over common obstacles like extension cords and ¾-in. stock. The easily engaged “kickstand” keeps the vac from rolling down slopes or through stair openings. All in all, it’s an enjoyable vacuum to use.

— Noah Kanter is the owner of Nth Degree Painting in Burlington, Vt. Patrick McCombe is a senior editor. Photos by Patrick McCombe.

From Fine Homebuilding #331

RELATED STORIES

• Drywall Sanding Tools and Materials
• Drywall Sanders
• The Drywall Sanding Process