DeWalt 1-1/2 in. PEX expander

First impressions and setup

I put the DeWalt PEX expander to work on a pair of bathroom rough-ins and a small mechanical-room re-pipe, running ASTM F1960 (expansion) PEX-A from 3/8 in. service runs up to a 1-1/2 in. trunk. Out of the box, this is a “tool-only” body, so you’ll need to bring your own 20V MAX battery and pick up expansion heads separately. DeWalt sells heads for 3/8–1 in., and there are 1-1/4 in. and 1-1/2 in. heads available as well. If you already live on the 20V MAX platform, setup is quick: pop in a charged pack, thread on the right head, give the collet a light dab of lubricant, and you’re ready.

A few details jumped out immediately. The right-angle design keeps the head compact and in line with the work, the long body provides two natural hand positions (upper and lower grips), and the onboard LED throws light where you’re expanding. There’s also a side hook that makes it easy to hang on a ladder or rafter between expansions. Fit and finish feel like the rest of DeWalt’s XR line—tight tolerances, rubber overmolds where you want them, and a brushless motor that spools up smoothly.

Ergonomics and balance

This expander is not a featherweight. Most of the mass is forward, between the head and gearbox, and you notice that during a day of overhead work. The two-grip body helps a lot; I tend to keep my lead hand up near the head to steer and my rear hand on the main grip to support and trigger. For body-height work or bench assemblies, the weight is a non-issue and actually helps keep the tool planted and steady through multiple expansions. For ceiling work, I recommend pairing it with a 3.0Ah compact battery to trim some weight, and use the hang hook as a “parking spot” during layout and ring placement to spare your forearms.

The trigger response is excellent, with a predictable ramp-up that lets you feather the first expansion or go full speed on repeat cycles. The head rotates automatically between cycles, which saves your wrist and keeps expansions even without having to think about orientation.

Performance on 3/8 in. through 1-1/2 in.

Across the common sizes—3/8, 1/2, 3/4, and 1 in.—the expander is quick and consistent. The auto-rotating head produces smooth, symmetrical expansions that slide over fittings without the lopsided feel you sometimes get from manual rotation. I especially appreciated the control on 3/8 in. lines where it’s easy to overdo it with less refined tools; here, it’s predictable and repeatable.

On the big stuff (1-1/4 and 1-1/2 in.), the brushless motor has enough torque to keep cycling without bogging, and the right-angle nose makes it easier to stay square to the tubing. You still need to respect the material: give cold PEX-A a little warmth in winter, keep a steady rhythm of expand-rotate-expand, and hold the fitting seated as the tubing shrinks. The tool’s pace makes that process efficient without feeling rushed.

Working in tight spaces

The 90-degree gear case is a genuine advantage between studs and joists. I could sneak the head into wall cavities where a straight-barrel expander would’ve required cutting back more drywall. The long, narrow body means you can choke up for control and still keep your forearm out of the stud bay. The LED isn’t floodlight-bright, but it’s bright enough to see ring placement and check for uniform expansion in dim corners.

A minor quirk: close to inside corners, the head’s collar can brush the stud face. It didn’t stop me from completing expansions, but it occasionally required a small adjustment in approach angle. Not a deal-breaker, just something to be mindful of in tight framing.

Speed and consistency

The auto-rotating head is the headline feature, and it earns its keep. Even expansions mean faster insertions and fewer redo’s, especially on 1 in. and up where small inconsistencies cause fitment hiccups. My workflow settled into a reliable cadence: slide the ring, align, expand, re-index automatically, expand again, insert the fitting, hold, move on. There’s less mental overhead when the tool handles rotation.

Noise and vibration are modest for a tool doing this kind of work. You feel the cam action, but it’s smoother than most corded models I’ve used and less buzzy than some compact expanders. Over a long day, that matters.

Battery life

DeWalt cites up to 81 expansions on 1-1/2 in. PEX-A with a 5.0Ah battery, and while conditions always vary, the brushless drive is efficient. On mixed-size days, I was comfortable running a 5.0Ah pack for a good chunk of work without babysitting the gauge. On pure large-diameter days, I grabbed a second battery to avoid any downtime. If you’re doing a lot of 1-1/2 in., plan for a mid-day swap; for smaller sizes, a single 5.0Ah will carry you farther than you might expect.

A practical tip: for overhead runs, a compact 3.0Ah makes the tool noticeably less fatiguing, and the runtime hit is acceptable when you’re mostly on 1/2 and 3/4 in.

Accessories, tracking, and serviceability

You’ll need to budget for expansion heads. The 3/8–1 in. range covers most residential work, and the larger heads are available for those who run 1-1/4 and 1-1/2 in. regularly. The head change process is straightforward and secure. Keep the spindle and segments clean and use a dab of approved lubricant to maintain smooth action, especially if you’re working in dusty framing environments.

The tool is CHIP-READY, meaning there’s a pocket for DeWalt’s Tool Connect tracking chip. On a busy job with multiple expander bodies and heads floating around, being able to tag this one is handy. There’s also a sturdy side-mounted hook that I used constantly—tiny feature, big quality-of-life improvement.

Service-wise, you’re covered by DeWalt’s 3-year limited warranty, a year of free service, and 90 days satisfaction guaranteed. That’s competitive in this category.

What I liked

• Auto-rotating head delivers even, repeatable expansions without thinking about indexing.
• Right-angle design and long body make tight-stud work and overhead runs easier.
• Brushless motor provides smooth power with respectable battery efficiency.
• Onboard LED and side hook add real-world convenience.
• Full size range from 3/8 in. to 1-1/2 in. covers residential and light commercial needs.

What could be better

• Weight is noticeable, particularly with a 5.0Ah battery and the larger heads. Overhead days will fatigue your arms.
• Heads, batteries, and charger are all sold separately; if you’re not already on 20V MAX, the buy-in adds up.
• The LED could be brighter and more diffused; it can cast a shadow right behind the head in very dark cavities.

Tips from the field

• Keep the expander head clean and lightly lubed to prevent chatter and ensure smooth expansion.
• In cold weather, gently warm the PEX-A and rings before expanding; it speeds recovery and reduces waiting time.
• Mark insertion depth on fittings so you can confirm full seating while the tubing shrinks back.
• Use a compact battery for overhead tasks and a 5.0Ah for bench or body-height work to balance fatigue and runtime.
• Let the auto-rotation do its job—don’t fight it or try to “help” by twisting the tool.

Bottom line

The DeWalt PEX expander hits the key marks I look for in an expansion tool: consistent, even expansions; practical ergonomics for real-world spaces; and enough power to handle large-diameter PEX-A without drama. It’s on the heavier side, and the modular approach—tool only, heads sold separately—means the total cost depends on your kit. But the performance is there, the usability is thoughtful, and the brushless drive and right-angle head make day-to-day work smoother.

Recommendation: I recommend this expander to plumbers and installers already on DeWalt’s 20V MAX platform or anyone who values an auto-rotating head and right-angle form factor for tight spaces. If you do lots of overhead work, plan on lighter batteries and take advantage of the two-grip body to manage the weight. For mixed-size residential and light commercial jobs, it’s a reliable, efficient tool that keeps pace with the demands of ASTM F1960 systems.