Abstract: An improved power tool system includes a power tool having a motor and a controller enclosed within a motor and controller housing, with the motor and controller sealingly coupled with the motor to prevent liquids and gasses from entering the motor and controller housing. In one aspect, the motor and controller housing comprises first and second interfitting components. In another aspect, a fixture for manufacturing a motor and controller housing includes a base with first and second angularly disposed support surfaces, and a pressing member received between the first and second support surfaces.

Abstract: An improved power tool system includes a power tool and an external power supply connected via a cable to provide utility and safety in a hazardous operation such as loading ammunition into a weapon in an environment of flammable materials and extreme environmental exposure. The power tool includes a sparkless motor, a sparkless controller and sparkless switches, in a sealed enclosure with improved heat transfer means. The power tool has improved torque controlling means to mitigate reaction torque to the operator and equipment when starting or stopping highly inertial loads. A sealed enclosure is provided to prevent liquids from entering the motor and controller cavity and includes a thermally conductive path to conduct heat from the motor and controller through the enclosure to cooling fins and a coolant path formed between the fins and an entrapment wall.