DeWalt 20V MAX XR 18 in. Bandfile Kit

Tight corners around a weld seam are where a bandfile earns its keep, and that’s precisely where the DeWalt 18-inch cordless bandfile has been living in my kit. I’ve been using it on sheet metal patches, small weld cleanups, and deburring brackets—jobs that normally push me toward a pneumatic finger file. Going cordless here changes the workflow more than I expected, and the balance of power, control, and reach makes this tool feel thoughtfully executed rather than just a corded/air replacement with a battery slapped on.

Setup and first impressions
The kit arrives ready to work: a compact POWERSTACK 1.7Ah battery, a charger, and two 80-grit belts. That grit is ideal for rough shaping and knocking down welds, but you’ll want to stock up on finer grits for finishing—120/180 for blending and 240+ if you’re prepping surfaces for paint. The tool itself is compact, and the 104° rotating contact arm folds into a storage position that actually matters; it tucks into a drawer or bag without snagging everything around it.

Build and feature set
A few features stand out immediately:

• Brushless motor with up to 732 W (MWO): In use, it feels stout for its size. It doesn’t stall easily on small weld beads or when easing into an edge.
• Variable speed trigger plus a speed dial: The dial sets a ceiling, and the trigger gives you feathering control. That pairing is excellent for preventing instant gouges when your belt first touches down.
• 104° rotating contact arm: Access is the point of a bandfile. Being able to rotate the arm lets me swing the belt into brackets, flanges, and inside corners without contorting my wrist.
• Tool-free belt changes: The belt swap takes seconds, even with gloves on. That reduces the temptation to “make do” with the wrong grit.
• Rotatable LED: Subtle but useful. I angle it to cut glare or to throw light precisely where the belt hits, particularly under dashboards and inside wheel wells.
• TOOL CONNECT chip ready: If you manage a fleet of tools, that’s handy. The chip isn’t included, but the cavity is there.

Ergonomics and control
Weight is manageable at about 4.6 lb, and the tool stays one-hand friendly. With the compact battery installed, the balance is toward the head—expected for a bandfile—and it helps keep pressure consistent without bearing down. The grip shape encourages a straight wrist in awkward positions, and the trigger response is predictable. I found the most consistent results using the speed dial at mid-range and feathering the trigger for first contact, then rolling into more speed as the belt stabilizes on the work.

Vibration is present but not fatiguing, and because the belt speed can run up to 5,600 ft/min, you’ll want to let the tool do the work. Push too hard and you’ll glaze belts or heat thin sheet metal unnecessarily. With ear and eye protection (and a face shield for sparks), it’s perfectly manageable for sustained use.

Performance
This bandfile has the grunt to remove material quickly when you need it and the finesse to finish without scalloping. On mild steel, 80-grit at higher speeds knocks down TIG tack welds faster than I expected for a compact belt file. The belt tracking on my unit has been stable—no constant tweaking needed—and I didn’t run into wandering belts when easing around a radius.

For finishing tasks, the dual control scheme shines. With the dial capped low, I can set the trigger just above stall and blend without skating across the surface. That’s particularly useful on automotive sheet metal edges or when you’re chasing a scratch pattern in a tight space where a random orbit sander can’t reach.

On plastics and softer metals (aluminum, brass), the low end of the speed range prevents immediate clogging and smearing. Still, keep a light touch and clean or swap belts as needed; a fresh belt is faster and cooler than “saving” a dull one.

Battery and runtime
The compact 1.7Ah POWERSTACK pack keeps the tool nimble and delivers solid punch for its size. Under continuous, aggressive grinding, plan on relatively short stints per pack—think a handful of minutes of real material removal before you’re dipping back to the charger. For quick touch-ups, deburring, and finish passes, the compact battery is perfect; the lower weight pays dividends when you’re working overhead or at arm’s length.

If you anticipate longer sessions—reworking a seam, dressing multiple brackets, or doing repetitive prep—this tool benefits noticeably from a higher-capacity pack. A 3.0Ah or 5.0Ah battery stretches runtime and keeps the motor supplied under sustained load, at the cost of some added weight. The included charger is basic but reliable; it’s not the fastest, so consider rotating multiple packs if you plan to lean on the bandfile all day.

Access and visibility
The rotating contact arm is more than a convenience. I routinely rotate it to sneak past obstructions and keep the belt flat to the work. In a wheel well, for example, I can bring the belt to the edge without the housing bumping into the contour. The rotatable LED gives you freedom to reduce shadowing and avoid blinding glare from fresh metal—small quality-of-life features that reduce mistakes when you’re working quickly.

Belt changes and maintenance
The tool-free mechanism is quick, and the belt stays on the pulleys securely. It’s worth noting that 18-inch belts are common and easy to source, so you’re not stuck hunting proprietary consumables. Keep a range of grits on hand and swap rather than fighting an inappropriate belt; it keeps heat down, surfaces cleaner, and your time better spent. Blow the tool out occasionally—metal dust accumulates—and keep an eye on the drive roller for embedded grit if you’re doing a lot of heavy removal.

Use cases where it shines
- Automotive and fabrication: Edge cleanup on patches, deburring brackets, blending welds in tight voids, fitting hardware where a grinder won’t reach.
- Metalwork finishing: Cleaning up inside corners, removing scale and slag precisely without chewing adjacent surfaces.
- HVAC, plumbing, and electrical: Notching, smoothing cut ends, and dressing edges in constrained spaces.
- Wood and plastics, cautiously: Trimming and shaping small areas where a larger sander is too blunt, using low speeds to avoid burning or melting.

What could be better
- Runtime out of the box: The included 1.7Ah battery is great for agility but short for heavy grinding sessions. Budget for a higher-capacity pack if you need longer pulls.
- Dust and spark management: As with most bandfiles, there’s no dust extraction. That’s fine for metal (expect sparks), but if you’re working wood or composites, plan on external dust control.
- Noise: It’s loud, again typical for the category. Ear protection is non-negotiable.
- Belt assortment: Only two 80-grit belts are included. A mixed grit pack in the box would help new users get from rough to finish without an extra purchase.

Value and who it’s for
If you’re already on DeWalt’s 20V platform, this bandfile integrates neatly—same chargers, same battery ecosystem. As a kit, it’s turnkey for anyone new to the platform, though power users will likely add a larger battery quickly. Compared to living on air, losing the hose is the headline advantage. You can get into a car, up a ladder, or inside a mechanical room without dragging a line, and you won’t be negotiating with a compressor for airflow. The brushless motor delivers consistent torque at the belt, and the upper end of the 5,600 ft/min speed range puts it in the realm of fast, decisive cutting for its size.

Practical tips from use
- Set the speed dial lower than you think, and bring in the trigger gently on first contact. It saves edges and prevents divots.
- Keep belts moving and use the length of the contact arm to spread heat. Pause frequently on thin materials.
- Stock grits in steps (60/80/120/180/240). Changing belts is faster than “making do,” and results improve dramatically.
- Rotate the LED to illuminate the contact point, especially in shadowy cavities where your body blocks overhead light.
- Consider a higher-capacity battery for long metal-removal tasks; balance is still good, and you reduce downtime.

Recommendation
I recommend the DeWalt 18-inch cordless bandfile for metal fabricators, auto body techs, and maintenance pros who frequently need precise material removal in tight spaces. It’s powerful for its size, the controls make it easy to avoid mistakes, and the rotating arm plus LED meaningfully improve access and visibility. The kit’s compact battery keeps it nimble, though heavy users will want a larger pack to extend runtime. If you’re looking to get air-hose performance without the hose, this bandfile earns a spot in the drawer you reach for first.