A friend who worked (very briefly) for Sears Hardware told me that the
training tapes for new employees mention that Sears holds its cost on power
tools down by using all recycled metals, plastics, etc. That would appear
to explain some of the low-quality issues.

Baloney! If you want junk they will sell you junk, if you want good stuff
they will accommodate you there also. They (just like others) try to have
something for all markets. The average person who walks in want a $50
router or circular saw and most likely has never used one and probably
won't use it once a year. On the other hand if someone who wants a better
quality they will also have that. Check out their 1617-12 router kit, it's
all
Bosch right down to the part numbers. RM~