I’m in the hunt for a new random orbital finishing sander.  I have noticed that not of all the DeWalt and Bosch models are available.  I do not have budget for a Mirka or Festool sanders nor their dust extraction systems.  I have considered looking at the sanders which have both a soft and hard pad and different sanding modes.   As you know, I am a hobby woodworker and quality is important.   I would like to hear from you.  What would you recommend?  What do you have and like?   Which ones do I stay away from?  Danl

I have the Dewalt 26541 5” variable speed and really like it. Not sure if that’s the current model. I my opinion, corded is the only way to go.

 

When random orbital sanders first came out, I bought a Porter Cable. It was heavy and bulky but it is still going strong. Then all the discs were PSA, Velcro is much more convenient and cost effective. 
 

The Dewalt is my goto for flat work 

I use a older Dewalt model, has been good for all these years.  (20)  Only ever had to replace the hook and loop pad once and the dust bag once.  My Dad had a Porter Cable unit and it got very little use over his 20 + years.  When I got it I ha to replace the hook and loop pad and a small rubber belt.  $12 fix.  Both work well.

My very early experiences with H&L pads left me less than ecstatic. The paper wouldn't stay put. Hopefully, they have improved. I'd sure like to convert my sanders to H&L. 

As to brand recommendations, my old faithful is the Porter Cable. But, the Makita ain't half bad, either. I'd really like to have this one, though. https://www.amazon.com/PORTER-CABLE-Random-Sander-Polishing-7346SP/dp/B002EQ96MG/ref=sr_1_25?dchild=1&gclid=CjwKCAjwybyJBhBwEiwAvz4G7zBUi90TJevwXWEmX8o8ZzOtexSMG_5NHKouDrLBS55X3ZVbPDMeyRoC6ysQAvD_BwE&hvadid=174229665343&hvdev=t&hvlocphy=9030226&hvnetw=g&hvqmt=b&hvrand=3403739053701001754&hvtargid=kwd-30666841&hydadcr=24661_9649005&keywords=orbital+sander&qid=1630492480&sr=8-25 the configuration looks to be easier on the hands. 

I've had a 5" Porter Cable for some time and have replaced the pad once. Good sander and it has held up well, I've had no other issues with it. I was gifted a DeWalt (DWE6423K) a year ago & I tend to use this more than the PC. Feels more confortable in the hand.

In my opinion if you want flat results with the wood then use a flat sander. I think the RO was originally made for auto work or at least where I sold tools and it suited the metal working guys just fine.

I have a PC 633 I think is the number. Five hole which you cannot get anymore. Have replaced the H&L pad once. Would be nice if it had a locking dust port for the hose, but as it is I took that little guy off and use and adapter to a 2 1/4 hose to the 4 inch DC. It is a little cumbersome but gets the dust which there hase to be a collection plan. I don't do much flatwork for last 10 years as most is on lathe now.

14 minutes ago, Gerald said:

Five hole which you cannot get anymore

Gerald, try these folks- https://www.supergrit.com/5-5-hole-mirka-gold-hl.html

 

I use a Bosch variable speed, corded ROS. I love it. I have not used any other ROS, so I have nothing to compare it to.  

I have the Bosch 3725 DEVS  5" random orbit sander. Does a great job but is a bit bulky for small projects  IE; "bandsaw boxes" with the cartrige dust collector attached. Otherwise, a great sander. 

My first one was a Sears Craftsman.  That thing sanded doors, walls, and table tops.  And, it did not come with H&L.  They were stickies.  It is still running but I did change the pad with a DeWalt H&L pad.  Gave it to my son who has never used it.  

 

The one I have now is like that of Gunny's.  It is a DeWalt about 20 years old.  It came with a bag so I can put in a variety of grits and have sander plus paper in multiple grits in a bag.  It is great.  

 

One suggestion, shop around the pawn shops.  They will be more affordable and some folks are dumping good tools right now as they are unemployed and cash in their tools to make ends meet.  

I have a Bosch variable speed that I got shortly after it was introduced.  At that time, I parked my Porter Cable 333 and have not used it since.  A few years ago, I got an intro deal on the Festool 150.  Then I got a lower quality Bosch that I use mostly as a loaner or for rough jobs.

 

I like the Festool, but I'm not sure it's enough better than my original Bosch to make the usual cost premium worthwhile.  One thing I like about it is that the speed does not race up when moving from one area to another.

 

I used a DeWalt during refinishing school.  I didn't care much for it*

 

Things I'd recommend:

• Variable speed via a trigger rather than a dial and on/off switch.  Way less chances of divots*
• Hook and loop pad to make changing grits between passes easier.
• "Start on" "Stop off" is the usual recommendation on how to stop and start the action when moving from one part to another.
• I hook them up to a shop vac hose for dust collection.  You might need to buy a new hose for this, but it's worthwhile.

I have an ancient 1/3 sheet Milwaukee from their Amstar days.  It's a beast weighing in at about 10 pounds.  I use this for larger jobs. It has no dust collection but still runs like a champ. 

 

Also run a Porter Cable 5" and a Porter Cable 1/4 sheet palm sander depending on the application.  Both of these have dust collection built in and have given great service.  I've had to replace the pad on the 5" once.

 

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I run a corded Makita single speed, it is a workhorse, the HL pad works great, and the dust extraction is excellent.

It is the best orbital I have used besides the air powered PC industrial ones we had at a cabinet shop I worked at.

Those things were insanely good but they are loud as hell and need a serious compressor to run them.

Have the Dewalt corded 5” model with H and L and like it. Dust collection port attaches well to the DC system. I agree they are not the best for flattening large surfaces. For that I use 1/2 sheet sanders. I have a Bosch 1/2 sheet which has been kind of a work horse. My son bought me one of these cheap ones for doing the boat deck and it works remarkably well for the money. I think it does the same job as the Bosch for a fraction of the price. 
Sheet Sander 1/2-https://www.amazon.com/dp/B09BJDWDM6/ref=cm_sw_r_cp_api_glt_fabc_M043PKVKK3W4CDD437MA

That link didn’t work. This is the sander