Abstract: An in-line profile sander is disclosed. The in-line profile sander includes a sander housing configured to be grasped by a user. A plurality of interchangeable profile sanding pads can be mounted at a head of the housing. The sander includes an in-line oscillating mechanism for moving the profile sanding pads in a linear oscillating motion.

Abstract: A method of making a wear and fatigue resistant component of a power tool (e.g., a clutch) includes providing a quantity of base steel and a quantity of alloying elements to be added to the base steel to form a desired alloyed grade of steel. The base steel and alloying elements are combined and melted to produce a molten alloyed steel (e.g., SAE 9310 or AISI M2). The molten alloyed steel is cast using a near-net-shape investment casting process to form a component of a power tool. An edge of the component is pre-radiused. and the component is case hardened after the edge of the component has been pre-radiused. In one implementation, the component is a clutch that has a lifespan of at least twice a lifespan of a second clutch that has not been pre-radiused prior to case hardening.

Abstract: An in-line profile sander is disclosed. The in-line profile sander includes a sander housing configured to be grasped by a user. A plurality of interchangeable profile sanding pads can be mounted at a head of the housing. The sander includes an in-line oscillating mechanism for moving the profile sanding pads in a linear oscillating motion.

Abstract: An in-line profile sander is disclosed. The in-line profile sander includes a sander housing configured to be grasped by a user. A plurality of interchangeable profile sanding pads can be mounted at a head of the housing. The sander includes an in-line oscillating mechanism for moving the profile sanding pads in a linear oscillating motion.

Abstract: A process for manufacturing highly wear and fatigue resistant steel components for power tools includes melting and mixing together a readily available base steel and alloying elements. The molten steel is cast into near-net-shape in an investment casting process. This method is cost competitive with forming the same component from steel with fewer alloying elements. In particular, clutch plates for a drill/driver or screw gun can be formed in this manner from a steel containing relatively large amounts of nickel and chromium, such as SAE 9310 steel, or from a steel containing a relatively large total amount of molybdenum and tungsten, such as AISI M2 steel.

Abstract: A depth adjusting system for a screw gun comprises a base supported on the screw gun, an on/off collar removably attached to the base, and an adjusting collar and a depth locator mounted to the on/off collar. The adjusting collar rotates but cannot move axially relative to the on/off collar. Rotation of the adjusting collar causes the depth locator to move axially relative to the on/off collar for adjusting the depth setting. An indexing system is provided between the adjusting collar and the on/off collar for retaining the angular position of the adjusting collar and the depth setting. The on/off collar can be easily attached and detached from the base with a simple axial force applied to the on/off collar.

Abstract: A depth adjusting system for a screw gun comprises a base supported on the screw gun, an on/off collar removably attached to the base, and an adjusting collar and a depth locator mounted to the on/off collar. The adjusting collar rotates but cannot move axially relative to the on/off collar. Rotation of the adjusting collar causes the depth locator to move axially relative to the on/off collar for adjusting the depth setting. An indexing system is provided between the adjusting collar and the on/off collar for retaining the angular position of the adjusting collar and the depth setting. The on/off collar can be easily attached and detached from the base with a simple axial force applied to the on/off collar.

Abstract: A depth adjusting system for a screw gun comprises a base supported on the screw gun, an on/off collar removably attached to the base, and an adjusting collar and a depth locator mounted to the on/off collar. The adjusting collar rotates but cannot move axially relative to the on/off collar. Rotation of the adjusting collar causes the depth locator to move axially relative to the on/off collar for adjusting the depth setting. An indexing system is provided between the adjusting collar and the on/off collar for retaining the angular position of the adjusting collar and the depth setting. The on/off collar can be easily attached and detached from the base with a simple axial force applied to the on/off collar.

Abstract: A clutch specially adapted for a screw gun includes an output clutch and a driving clutch. The output clutch is movable axially to engage the driving clutch. A helical spline arrangement on the driving clutch causes the driving clutch to move axially towards the output clutch a short distance when torque is transferred through the clutch. When the clutch slips and the torque is released, the driving clutch moves axially away from the output clutch a short distance and a gap is created between the output clutch and driving clutch which prevents clashing. Also, a retaining ring is mounted to an input spindle to limit the axial movement of the driving clutch.

Abstract: An in-line profile sander is disclosed. The in-line profile sander includes a sander housing configured to be grasped by a user. A plurality of interchangeable profile sanding pads can be mounted at a head of the housing. The sander includes an in-line oscillating mechanism for moving the profile sanding pads in a linear oscillating motion.

Abstract: A process for manufacturing highly wear and fatigue resistant steel components for power tools includes melting and mixing together a readily available base steel and alloying elements. The molten steel is cast into near-net-shape in an investment casting process. This method is cost competitive with forming the same component from steel with fewer alloying elements. In particular, clutch plates for a drill/driver or screw gun can be formed in this manner from a steel containing relatively large amounts of nickel and chromium, such as SAE 9310 steel, or from a steel containing a relatively large total amount of molybdenum and tungsten, such as AISI M2 steel.

Abstract: A clutch specially adapted for a screw gun includes an output clutch and a driving clutch. The output clutch is movable axially to engage the driving clutch. A helical spline arrangement on the driving clutch causes the driving clutch to move axially towards the output clutch a short distance when torque is transferred through the clutch. When the clutch slips and the torque is released, the driving clutch moves axially away from the output clutch a short distance and a gap is created between the output clutch and driving clutch which prevents clashing. Also, a retaining ring is mounted to an input spindle to limit the axial movement of the driving clutch.

Abstract: A depth adjusting system for a screw gun comprises a base supported on the screw gun, an on/off collar removably attached to the base, and an adjusting collar and a depth locator mounted to the on/off collar. The adjusting collar rotates but cannot move axially relative to the on/off collar. Rotation of the adjusting collar causes the depth locator to move axially relative to the on/off collar for adjusting the depth setting. An indexing system is provided between the adjusting collar and the on/off collar for retaining the angular position of the adjusting collar and the depth setting. The on/off collar can be easily attached and detached from the base with a simple axial force applied to the on/off collar.

Abstract: An in-line sander comprising a sander body which houses a motor coupled to an in-line oscillating mechanism. The in-line oscillating mechanism is adapted and configured to move a sanding pad in a linear oscillating motion.

Abstract: An in-line sander comprising a sander body which houses a motor coupled to an in-line oscillating mechanism. The in-line oscillating mechanism is adapted and configured to move a sanding pad in a linear oscillating motion. A corner or detail pad has a substantially flat lower surface and a substantially pointed front portion bounded laterally by two substantially-linear corner-sanding edges having an included angle of less than 90 degrees. A forward end of this substantially pointed front portion of the preferred corner or detail pad protrudes ahead of a front end of the sander body throughout the linear oscillating motion of the pad. The front portion of the preferred corner or detail pad has particular application for sanding into corners of a carcass.

Abstract: An in-line sander comprising a sander body which houses a motor coupled to an in-line oscillating mechanism. The in-line oscillating mechanism is adapted and configured to move a sanding pad in a linear oscillating motion. A corner or detail pad has a substantially flat lower surface and a substantially pointed front portion bounded laterally by two substantially-linear corner-sanding edges having an included angle of less than 90 degrees. A forward end of this substantially pointed front portion of the preferred corner or detail pad protrudes ahead of a front end of the sander body throughout the linear oscillating motion of the pad. The front portion of the preferred corner or detail pad has particular application for sanding into corners of a carcass.

Abstract: An in-line sander comprising a sander body which houses a motor coupled to an in-line oscillating mechanism, configured to move a sanding pad in a linear oscillating motion.A corner or detail pad has a substantially flat lower surface and a substantially pointed front portion bounded laterally by two substantially-linear corner-sanding edges having an included angle of less than 90 degrees. A forward end of this substantially pointed front portion of the preferred corner or detail pad protrudes ahead of a front end of the sander body throughout the linear oscillating motion of the pad. The front portion of the preferred corner or detail pad has particular application for sanding into corners of a carcase.A preferred embodiment of the present corner or detail pad has at least one substantially linear side edge which is aligned substantially parallel to the linear oscillating motion of the sander.

Abstract: The present invention relates to a sanding system which can be configured into many highly-versatile configurations. The present sanding system is arranged and configured to alternatively and selectably accept for use a corner or detail pad, a shutter pad, and a wide variety of profiled pads. Such versatility is found in no other sander.