DeWalt TOUGHSYSTEM 2.0 22 in. W Modular Tool Box

Field notes from a month with the ToughSystem 2.0 22-inch toolbox

I started using the ToughSystem 2.0 22-inch toolbox as a grab-and-go box for power tools and site essentials. It’s the mid-size workhorse in DeWalt’s modular lineup—compact enough to toss in a truck bed, large enough to swallow a couple of cordless tools, chargers, and consumables. After several weeks of jobsite use, rides in the back of a UTV, and a few weather events, here’s how it’s held up.

Build and first impressions

At 8.8 pounds empty, the box feels surprisingly stout without being a burden to carry. The body is high-impact polypropylene with ribbed reinforcements, and the lid closes against a continuous gasket to achieve an IP65 rating. I like the mix of materials: metal front latches for the main closure, plastic for the side auto-connect latches to keep weight down. The footprint—about 21.3 inches wide by 14.6 deep and 12.3 tall—fits neatly under a bench and in most truck compartments.

Inside, you get a removable tray that spans the width. It’s handy for high-frequency items—drivers, bits, oscillating blades, a tape, and a few batteries. Below the tray, the cavity is a clean box with internal dimensions roughly 19.5 by 12.1 by 9.7 inches. That’s enough to fit a 7-1/4-inch circular saw, or a drill/impact pair with chargers and a few boxes of fasteners. There’s no built-in divider system beyond the tray, so plan on pouches or foam if you want stronger organization.

Latches, stacking, and daily use

DeWalt’s auto-connect side latches are the biggest “2.0” change I noticed. They let you stack and lock boxes together with one hand; you drop a case on top and the latch snaps shut. It’s genuinely faster than older pin-and-slot styles, especially when you’re wearing gloves. The front latches—two-piece metal—close with a positive, confidence-inspiring snap and haven’t loosened up.

A few notes from the field:
- The side latches work best when the surfaces are clean. Grit can make the auto-connect action feel mushy; a quick brush-off fixes it.
- In cold weather (below freezing), the side latches stiffen. They still work, but I avoid slamming them closed to prevent long-term stress on the plastic.
- With a tall stack, the side latch housings can snag on straps or door frames. Not a deal-breaker, but you learn to carry and set the stack with that in mind.

This box itself doesn’t have wheels. If you’re making longer hauls, it’s meant to ride on a wheeled ToughSystem base or dolly. As with any modular tower, stability depends on the ground and how high you stack. On flat concrete, I had no issues rolling a stack of three across a site. On uneven ground, I keep the stack to two boxes or move the column with a strap to keep the center of gravity in check.

One inherent trade-off with modular towers: access. If you place this 22-inch box under other cases, you’ll need to unclip the ones above to get inside. I keep frequently accessed hand tools in the top case and heavier, less-used items lower to minimize reshuffling.

Capacity and weight handling

The rated load capacity is 110 pounds. I pushed it close by packing a circular saw, jig saw, drills, chargers, a couple of 5Ah batteries, a hole saw kit, and fasteners. The box flexed very slightly at the lid when I jumped on it, but the latches held and the seal remained intact. Carrying 80–90 pounds single-handed isn’t fun, yet the built-in handle stayed comfortable, with no bite points or noticeable twist.

If you intend to approach the full 110-pound capacity regularly, I’d pair this box with the wheeled platform to save your back. The plastic shell is tough, but like any polymer case, a cantilevered load (carrying from the side while the contents are off-balance) is harder on the handle and hinge than a centered lift.

Weather resistance and dust control

The IP65 rating is the real deal for this box. I gave it a five-minute hose test with a standard nozzle from multiple angles and found no water inside. It also rode the back of a UTV on dry, powdery roads; the exterior was caked, the interior was clean. The gasket does its job as long as the sealing surfaces are free of debris.

Worth noting:
- IP65 means protected against water jets and dust, not submersion. Don’t leave it half-buried in a flooded trench and expect a dry interior.
- Keep the gasket clean and lightly conditioned; fine grit on the seal can compromise it over time.

Durability under abuse

I treat storage as gear, not furniture. The box survived a tailgate topple (about 3 feet) onto compacted gravel with only cosmetic scuffs. The corners show smart energy-dissipating geometry, and the lid stayed square. The metal front latches inspire confidence; they close with authority and don’t deform under load.

The side auto-connect latches are the one area where I’m more careful. They’ve held up fine so far, but they are plastic, and it’s clear they’re designed for easy engagement rather than brute-force abuse. If you routinely slam stacks together, especially in cold weather, you’ll shorten their life. Treat them like a precision mechanism and they repay you with speed and convenience.

Compatibility and ecosystem

Backward compatibility is strong. This 22-inch box locks into other ToughSystem components, including older cases and the wheeled base. Mixing generations hasn’t caused me any odd fit issues; the auto-connect latches engage reliably, and the stack feels cohesive. If you already own ToughSystem cases, this drops in smoothly. If you’re starting fresh, the ecosystem gives you a clear path to expand—organizers for small parts, deeper boxes for bulk storage, and wheeled options for mobility.

Ergonomics and storage

The top handle is broad enough for gloved hands and folds flat without rattling. The lid opens fully without tipping the box backward. Inside, the tray lifts out cleanly and nests in inverted orientation if you want to clear the full cavity temporarily. There aren’t many nooks or molded tool slots, which I appreciate; it’s a blank canvas that takes foam, pouches, or bins without fighting the geometry.

Because the exterior dimensions are tidy, it stacks well in a van or under shelving. The flat lid also plays nicely as a temporary staging surface; I’ve used it to keep screws off the floor and to mark cuts, and it wipes clean without staining.

What could be better

• Side latch toughness in the cold: The auto-connects get stiff and feel more brittle below freezing. They’ve held up for me, but I handle them gently in winter.
• Tray depth: The included tray is useful, but a tad shallow. A modular, deeper insert option would help corral bulkier hand tools without sacrificing the main cavity.
• Access in stacks: This is a system reality, not a flaw of the box itself, but it’s worth planning your layout so the kit you reach for most is at the top.

Who it suits best

• Tradespeople and DIYers who value weatherproof storage and already own (or plan to build) a ToughSystem stack.
• Mobile users who move between truck, site, and shop and need a sealed, mid-size box for power tools and accessories.
• Anyone working in dusty or splash-prone environments where an IP65 seal keeps downtime and cleanup to a minimum.

If you need frequent, top-down access to many small items, a dedicated organizer with drawers might serve you better. And if you’re routinely moving 100-plus pounds over distance, consider pairing this with the wheeled base rather than carrying it solo.

Recommendation

I recommend the ToughSystem 2.0 22-inch toolbox as a durable, weather-sealed middle box that plays exceptionally well inside its ecosystem. It’s tough where it counts—shell, hinges, and metal front latches—while the auto-connect side latches make stacking faster and less fussy than older designs. Treat those side latches with a bit of respect, especially in cold conditions, and you’ll get a reliable, dust- and water-resistant box that protects tools and simplifies transport. For users committed to the ToughSystem platform or looking for a resilient, mid-size toolbox with real IP65 performance, this one earns a spot in the stack.