Mid-handle drill construction and assembly process

A power tool comprising:

• a motor;
• a self-contained gear case assembly comprising a metal gear case defining a cavity at one end, and a substantially planar cover plate;
• a field case defining a generally cylindrical chamber for receiving the motor, the field case having a front portion configured for engaging the gear case assembly and a rear portion;
• and
• a housing assembly partially defined by the field case and including first and second generally symmetrical housing segments forming a mid-handle grip and configured for engaging the field case and gear case;
• wherein the cover plate is secured to the gear case thereby closing the cavity and is not removably accessible from an exterior of the power tool.

A method of assembling a mid-handle power tool, comprising:

• providing a housing assembly having first and second generally symmetrical housing segments, the housing segments together defining an end cap and a mid-handle grip integrally joined by a bridge section;
• connecting a first set of lead wires to a motor;
• routing the first set of lead wires to the front portion of a field case while pressing the motor into the field case from the front portion;
• attaching a gear case to the field case;
• attaching the field case to the first housing segment;
• and
• attaching the second housing segment to the field case and the first housing segment.

A power tool comprising:

• a gear case;
• a motor having a first set of lead wires;
• a field case defining a generally cylindrical chamber for receiving the motor, the field case having a front portion configured for engaging the gear case and a rear portion;
• a housing assembly partially defined by the field case and including first and second generally symmetrical housing segments configured for engaging the field case and forming a mid-handle grip;
• a trigger switch assembly;
• and
• a fan unit disposed in the field case and operable to vent at least one of the motor and the gear case,
• wherein the field case comprises at least one venting aperture in fluid communication with an interior of the mid-handle grip and configured to allow the intake or exhaust of air flow there through,
• further wherein the first set of lead wires is routed from the motor through the front portion of the field case and through a retaining slot adjacent the venting aperture to the trigger switch assembly and the fan unit is positioned to secure the lead wires in the retaining slot.

A method of assembling a mid-handle power tool, comprising:

• providing a housing assembly having first and second generally symmetrical housing segments, each housing segment forming a portion of an end cap and a portion of a mid-handle grip integrally joined by a bridge section;
• connecting a first set of lead wires to a motor;
• routing the first set of lead wires to the front portion of a field case while pressing the motor into the field case from the front portion;
• attaching a gear case to the field case;
• attaching the field case to the first housing segment;
• attaching the second housing segment to the field case and the first housing segment;
• connecting a second set of lead wires to the motor;
• and
• routing the second set of lead wires from the motor through a rear portion of the field case and along the bridge section of the first housing prior to attaching the second housing segment.