Thinking about investing in a SurfPrep sander but not sure which one’s right for you?
In this post, I’m breaking down what I’ve learned from using both the 3″x4″ Electric Ray and the 6” Random Orbital Sanders in my woodworking and sign-making business.
If you find this helpful and decide to try SurfPrep, I’d love it if you used my links and the code KENDRA to save 10% — it helps support what I do, and I really appreciate it!
Let’s Back It Up: My Sander Saga
Before we get into SurfPrep, let’s rewind a bit. Hopefully, my journey will save you from spending hundreds (or thousands) of dollars like I have over the years.
My very first sander? A Dremel MultiMax. And yes, I once sanded an entire 4’x10’ table with it. Technically, it counts as my first electric sander…
After that came a cheap little mouse sander. Then a couple of RYOBI orbitals. When those didn’t have enough power, I moved on to a Bosch 6″ orbital, which eventually got replaced with another Bosch. That one had so much vibration that it left my hands numb.
Finally, I invested in a Mirka 6″ orbital sander, and that was a dream. Quiet, smooth, powerful. This was my proof that when it comes to tools, you really do get what you pay for.
It was a few years after buying the Mirka that I added the SurfPrep 3”x4” Electric Ray to my tool setup. I knew it would be perfect for sanding cutout pieces I shape with my rotary tool, and it did not disappoint.
Eventually, when my Mirka orbital stopped working, I took it as the excuse I needed to try a SurfPrep orbital, and that’s where this post begins.
Now, my two most-used sanders are the SurfPrep 6” Electric Ray Random Orbital and the SurfPrep 3”x4” Electric Ray.
Why SurfPrep? Why Two?
I don’t build furniture or pour massive epoxy river tables. I make signs and layered wood art. So… do I really need an expensive sander? And two of them?
Yes. But also… no. It depends.
Here’s the thing — they’re great for different tasks.
The SurfPrep 3"x4" Electric Ray Sander
I use this one for almost everything. It’s perfect for shaped wood cutouts, letters, ornaments, and getting into corners and weird spaces. It’s lightweight, easy to hold, and super comfortable to work with for long periods of time.
There’s very little vibration, which makes a huge difference when you’re sanding for hours. It saves my wrist and my sanity. It does an amazing job on contours and curves, especially when paired with SurfPrep’s ProFoam pads.
The SurfPrep 6" Random Orbital Sander
This one comes out when I need power. I mount my shaped pieces onto backers (often hardwood), and I need something that can smooth those fast. The 3×4 just isn’t built for that kind of surface area.
SurfPrep orbital sanders come in two sizes — 5” and 6” — and two orbit options:
- 3/16″ Orbit (more aggressive)
- 3/32” Orbit (smoother, more refined finish)
Since I’ve used a 6” sander for years, I stuck with that and chose the more aggressive orbit.
I don’t always need all that power, but when I do, this thing is a beast. It tears through uneven spots, glue, and (laser friends…) engraving mistakes. It has already helped save a few projects.
But the best part? It’s unbelievably smooth to operate.
As aggressive as it is, there’s almost no vibration in your wrist or arm. That’s one of the biggest benefits of a high-end sander: all the power, without the pain in the wrist that tends to come after.
Both sanders also have variable speed control, making it easy to slow down for more delicate work, or speed it up when I need the power.
Quick note:
When choosing size, 5” is the industry standard for orbital sanders, and usually fine for most. I stuck with 6” because I already had a ton of 6” sanding discs, including ProFoam.
Speaking of ProFoam… Let’s Talk About It
You can use SurfPrep’s ProFoam Sponge Abrasives with just about any sander — they make them in all the standard sizes. So technically, they’ll fit whatever you’ve got.
Because I loved how they performed on my 3×4, I picked some up for my Mirka too. I figured, great sander, great paper, perfect match. I was surprised to find out, though, that I didn’t love them together. So it wasn’t a combo I kept using.
When my SurfPrep orbital arrived, I gave the ProFoam another try, and I was genuinely blown away by how well that pairing worked.
Turns out, there’s a reason for this…
SurfPrep’s sanders are actually designed around their foam abrasives. The pads have more flexibility, and the orbital motion is optimized for foam, resulting in better surface contact, smoother finishes, and more control on detailed or contoured work.
That’s not a knock on the Mirka, I still love that sander (so much so that I paid to have it repaired). It’s just not made to work with foam. It was a major bonus that the SurfPrep that I originally wanted for my sign backers is now my go-to for live-edge pieces and curved or rounded edges.
Dust Control
Yes, it’s another investment. But it’s worth it.
If you’re still sanding without a dust extractor hooked up, please consider making the leap. Not only is it better for your lungs, but your sanding results improve too because you’re not grinding the same dust back into your work. Not to mention it saves you a ton of cleanup.
I’ve used:
- A Fein Dust Extractor – affordable, worked fine with the 3×4
- A Festool Dust Extractor – I switch this one between tools (including the two SurfPrep sanders), and it’s always been great
- The SurfPrep Dust Extractor – I’ve used this since November 2023 and haven’t changed the bag once. I’ve even run two sanders off it at once.
SurfPrep’s vacuum includes an automatic self-cleaning filter system, which helps extend the life of the filters and bags, meaning less maintenance and fewer replacements.
Keep in mind SurfPrep’s extractor is designed to work seamlessly with their sanders, so check their vacuum attachment disclaimers for safety, and if you’re unsure about compatibility, their customer support chat is super helpful.
So… Which Sander Should You Choose?
Both, of course!
Okay, I’m kidding.
You could do all your sign work with just the orbital. I went years without the 3×4 and managed fine. But now that I have it, I wouldn’t want to go back. The 3×4 paired with ProFoam saves me time and has improved the quality of my work overall.
That said, until now, I wasn’t fully aware how well the orbital worked with ProFoam. If you go with the 5” and slow the speed, you could likely use it for sanding smaller cutouts, too. I think my 6” would be a bit big for that type of work, but in a pinch, I bet I could make it happen.
On the other hand, depending on what you make, the 3×4 might actually cover most of your needs. It’s great for:
- Small pieces
- Laser char
- Shaped cutouts after rotary carving
- Backers that don’t need heavy surfacing
- Contours and tight corners
There are tons of sandpaper options for it, too — it’s not always all about the foam.
Is a SurfPrep Worth the Investment?
A SurfPrep sander, no matter which one you choose, is a game changer.
Honestly, any well-built sander is. That’s why they cost what they do. You’re getting a smoother operation, better control, and significantly less vibration, especially when paired with a proper dust extractor.
That said, it’s only a game-changer if you’re sanding enough to make it worth it. I use my sanders daily, so having tools I enjoy working with (instead of dreading) matters.
Still Deciding? Here’s What I’d Recommend
➡️ If you’re not currently using an orbital sander, and you’ve been getting by without one, or if your orbital is fine, but you want something in addition, go with the 3×4. It is an amazing little sander.
I just don’t recommend it as a replacement for an orbital if you work with large flat pieces like backers or cutting boards.
➡️ If you need an orbital sander or you hate your current one, get the orbital.
The difference in vibration alone is night and day compared to cheaper models. And that’s not even considering all the other perks.
🛠️ And long-term?
Pairing SurfPrep’s orbital sander with their 3×4 is the perfect combo. You get the power and speed of the orbital, and the control and finesse of the 3×4 for detailed or finishing work. You don’t need to buy both at once; start with the one that fits your current workflow. If the other becomes necessary down the line, you’ll already know how well they work together. These tools are an investment, and your business (and your body) are worth investing in.
Final Buying Tips
You can purchase SurfPrep sanders alone or as a full system, which includes a variety of sandpapers.
With both of my sanders, I got the full kit. This was a great way for me to test out all the different paper SurfPrep has to offer.
3″x4″ Electric Ray Sander:
For my 3×4, I find I use the 10mm Firm ProFoam in medium and fine grit most often. For standard paper, I like their Blizzard Film Abrasives.
Random Orbital Sander
You’ll need to choose between 5” and 6”, and between the 3/32” and 3/16” orbit.
6” Full Sanding System (mine is the 6” with a 3/16” orbit)
Final Notes
My SurfPrep 6” orbital sander was provided; however, I previously purchased the 3×4, their vacuum, and of course, loads of ProFoam paper. This post is an honest breakdown to help you decide which sander makes the most sense for your workflow.
🛠️ Got questions? Drop a comment below — I’m happy to help!
💸 And don’t forget to use my discount code: KENDRA at checkout to save on your SurfPrep order. If you found this post helpful, using my links and code is a great way to support what I do.
If you’d like to see the finished wood signs I use these sanders on, or shop my digital cut files to make your own, click here to visit my homepage.
Thank you for this info! I’m new to this style of lasering and am entirely blown away by beautiful these pieces are.
Thanks for reading and for your kind words!
Thank you this was actually incredibly helpful we’ve been looking for a new sander and yes know what you mean having numb hands at the end of a project. Still want both but this was very helpful!
Thanks so much for reading! I am so glad it was helpful!
Great post! I’ve been looking for a new sander now for a while— think I’m going to get the 3×4 to start!
Thanks for checking it out! It’s a good choice!
Fantastic to read through this blog post! I really appreciate the written words for deeper comprehension. I use videos also, but the depth of your explanation in your blog is super helpful! My greatest challenge with my orbital is the numb hands after sanding for long periods. Thank you Kendra!
Thanks so much for reading, I am so glad it was helpful!