DeWalt Pneumatic Palm Sander

A compact, capable air sander for fine finishing

My first session with the DeWalt palm sander was on a set of maple cabinet doors that needed a uniform, swirl‑free surface before lacquer. Later that week, I used the same tool to prep a primered fender for paint. In both jobs, this pneumatic random orbit sander did what a fine‑finish palm sander should do: stay controlled, leave a consistent scratch pattern, and run all day without drama—provided your air system keeps up.

Build, feel, and controls

The composite body keeps the weight reasonable for a 6-inch platform. It’s not featherweight, but the weight is centered and the profile is low, which helps you keep the pad flat. The top is easy to palm, and the sides give you enough purchase for guiding with your fingertips along edges. I especially like that the body doesn’t chill my hand as much as aluminum-bodied pneumatics do; the composite construction and rear exhaust make a difference in comfort on longer sessions.

DeWalt uses a touch-control trigger instead of a palm lever. Out of the box, I could meter the speed and aggressiveness by how hard I squeezed, which is great for feathering edges or easing into curves. If you’re used to a big palm throttle, the trigger feel is different; I found it more precise for detail passes, though it can fatigue your index finger a bit in long continuous sanding.

Orbit and finish quality

This model runs a 3/32-inch orbit at a free speed of up to 12,000 RPM (at the typical 90 psi). That orbit size is the headline here. It’s tuned for finish work: think final leveling, primer scuffing, and sanding between coats rather than heavy material removal. On the cabinet doors, stepping through 120 → 180 → 220 left a tight, uniform scratch pattern that hid easily under a sealer coat. On the automotive panel, it knocked down nibs without chasing new swirls. If you need to hog off stock or strip finishes quickly, you’ll want a 3/16-inch orbit sander; the DeWalt is the tool you reach for once the heavy lifting is done.

Pad and abrasives

Mine came set up for 6-inch PSA discs (pressure-sensitive adhesive). PSA holds flat and true, and with a 3/32-inch orbit the pad tracks cleanly across edges without the “skating” you sometimes get with hook-and-loop on harder surfaces. Changing discs is quick—peel and stick—but mid-project grit swaps aren’t as fast as velcro if you’re constantly bouncing between two grits. The upside is a very secure, full-contact bond that resists pad slip on high-speed passes.

There’s a keyless pad release on the sander, which makes it easy to swap backing pads by hand. I keep a firm pad on hand for flatter surfaces and a soft interface pad for contours and bumper covers; the ability to swap without hunting a wrench is a practical win.

One note: make sure you’re buying 6-inch PSA discs, not 5-inch or hook-and-loop. The 6-inch size covers more area per pass and suits automotive and cabinet work, but the discs are slightly pricier than 5-inch. The common grits are widely available.

Air requirements and shop setup

DeWalt lists the free speed at 12,000 RPM at 90 psi, and you’ll want a compressor that can deliver steady air. Retail numbers suggest around 5 CFM at 90 psi, but in real use a random-orbit sander is a continuous draw tool. If your compressor can’t keep up, the speed drops and finish quality suffers. In my shop, a 20–30 gallon belt-drive unit in the 5–8 SCFM range handled the sander for cabinet runs with occasional rests; for uninterrupted automotive prep, a larger twin-cylinder setup is ideal. Pancake and small portable compressors will run it in short bursts but cycle frequently and heat up.

If you run air tools regularly, add a water separator and a light oiler in the line. A couple drops of pneumatic oil before each session keeps the motor smooth and the trigger modulated. DeWalt includes a small bottle of oil, which is a nice touch. Keep pressure around 90 psi at the tool; higher isn’t better here and can drive up chatter.

Dust, noise, and exhaust

As a non-vacuum pneumatic, this sander doesn’t integrate dust collection. The rear exhaust port keeps blast out of your work area, which is good for surface quality, but it still throws fines into the air. In a booth, that’s manageable; on a bench, pair it with a downdraft table or external extraction to keep dust in check. The rear exhaust is also relatively comfortable—it doesn’t blast cold air at your hand—but like all pneumatics, the tool is loud at high speed. Hearing protection is a must, and I’d add a mask anytime you’re sanding finishes or primer.

Power and control in use

With the trigger feathered in, the sander starts smoothly with little tendency to gouge. Full squeeze gets you near free speed, and the pad stays stable at that pace thanks to the smaller orbit. On wide, flat panels, I could cover ground quickly with 6-inch discs while keeping my scratch pattern tight. Along edges, backing off the trigger and letting the pad float prevented burn-through on veneer and made it easy to blend transitions on the fender.

Vibration is well controlled for a pneumatic in this class. After an hour of cabinet work, I didn’t feel that telltale tingle in the fingertips, and the composite body isolates some of the chill. If you run it constantly for auto prep, take regular breaks—or use anti-vibration gloves—as you would with any high-speed sander.

Durability and service

The build feels solid. The composite shell has handled knocks around the booth, and the internals haven’t developed slack or chatter with routine oiling. DeWalt backs the tool with a 90-day money-back period, a one-year free service contract, and a three-year limited warranty. That’s generous for a pneumatic in this price bracket and gives some peace of mind if this is your first air sander.

Where it shines and where it doesn’t

Strengths:
- Finish-first orbit (3/32 inch) produces a tight, low-swirl scratch pattern
- Variable trigger provides fine speed control for edge work and blending
- 6-inch platform covers area efficiently for cabinets and body panels
- Composite body is comfortable and doesn’t get ice-cold in use
- Keyless pad swaps make it easy to change backing pads

Tradeoffs:
- PSA discs are secure, but less convenient than hook-and-loop for frequent grit changes
- No integrated dust collection; external extraction is on you
- Needs a real compressor; small portables struggle on continuous runs
- Trigger actuation can tire your index finger in long sessions

Value and alternatives

In the shop, I usually slot this sander between an aggressive 3/16-inch orbit tool and a detail sander. It’s the one I grab for final leveling on wood, primer scuffing before sealer, and between-coat sanding when I’m chasing consistency over speed. Premium pneumatics at twice the price can be a touch smoother and lighter, and some offer vacuum-ready pads. If you need constant, dust-controlled production sanding, those features matter. For most small to mid-sized shops—especially those already set up for air—the DeWalt hits a sweet spot of capability, comfort, and cost.

Tips for best results

• Feed it clean, dry air at 90 psi and oil before each use.
• Use a soft interface pad on curved parts and a firm pad on flat panels.
• Step through grits thoughtfully; the 3/32 orbit rewards proper grit progression.
• Keep the pad flat and let the sander’s weight do the work—don’t lean.
• Pair with external dust control for cleaner work and better finishes.

Recommendation

I recommend this DeWalt palm sander for anyone who needs a reliable, fine-finish pneumatic in a 6-inch format—cabinet shops, hobby woodworkers with a capable compressor, and automotive DIYers or pros doing primer and paint prep. It produces a clean, low-swirl finish, the trigger gives excellent control, and the composite body keeps it comfortable. You do give up integrated dust collection and the convenience of hook-and-loop discs, and you’ll need a compressor that can keep up. If those tradeoffs fit your workflow, it’s a well-balanced, durable sander that earns its spot on the bench.