Pad size does make a difference, for a number of reasons.
1.
There is quite a bit more surface area in play when using the 6-1/4" disc compared to the 5-1/2" disc ... about
29.12% more:
Imagine if you dropped machine speed 29.12%, or had 29.12% less random rotation of the backing plate. That would be a big deal. So depending upon what you are trying to accomplish, the increase in surface area may be beneficial or detrimental. It just depends upon the task at hand.
2.
When using a maximum speed setting in hopes of creating rapid backing plate rotation, a larger pad will spin at a higher rate of speed for a given RPM, assuming friction doesn't enter into the equation.
If we
do not take into consideration the
speed of the mechanically driven orbit nor how
friction affects backing plate rotation, but instead focus
only on overall rotational
speed:
A 5-1/2" disc spinning 10 times per second has an outer edge speed of about 9.8 MPH
A 6-1/4" disc spinning 10 times per second has an outer edge speed of about 11.2 MPH.
That's about
14.3% more
speed.
3.
Considering how friction might affect backing plate rotation:
We would need to know whether "X" amount of weight and pressure placed upon a
small area would slow backing plate more than if it was spread over a large area. That would be interesting for sure.
4.
Procedure plays a big part in the choice of pads. For example, if you tend to tilt the machine in order to focus applied pressure or machine motion (or polishing energy), then you'd have to tilt the machine
more in order to create the same sized
footprint upon the paint as a smaller disc would.
In fact, you don't even need to tilt the pad for this dynamic to occur. A panel featuring even a modest curve or bulge would net a similar effect.
Note:
I think that
tilt is one of the reasons some guys aren't too keen on using the
Flex XC 3401VRG with the
Meguiar's Microfiber Discs.
After all, the discs don't use overly squishy foam, so machine motions are transferred through the foam to the microfiber material very efficiently. When the machine is tilted even a little, the concentration of pressure and the machine's forced rotation tries to rotate the pad like a tire, taking the polishing guy along for the ride.
This is why I posted on another forum that Zoh6 give an interface pad a try... stick one between the backing plate and a Microfiber Disc.
The Flex has a relatively large orbit (5/16" diameter orbit) compared to the Festool Rotex RO150FEQ (3/16" diameter orbit) or the Makita BO6040 (7/32" diameter orbit).