DeWalt TOUGHSYSTEM 2.0 22 in. Extra Large Toolbox

Why this XL box stuck around in my workflow

I’ve been hauling tools in and out of job sites long enough to know a storage box either earns its keep in the first week or becomes dead weight. The ToughSystem 2.0 XL box landed in the first camp. It’s a big, IP65-rated bin with a simple promise: take bulky, heavy gear, keep it protected, and stack neatly with the rest of the system. After months of loading it with everything from cordless compressors to impact kits and test instruments, here’s where it impresses and where it needs refinement.

Build quality and design

The shell is polypropylene and feels stout without being needlessly heavy for its size. Empty, it’s 14.7 pounds; filled, I’ve regularly run it in the 60–90 pound range without a hiccup. The two-piece metal front latches are the highlight. They’re positive, easy to find by feel with gloves on, and clamp the lid securely over the perimeter gasket.

The side auto-connect latches are the hallmark of ToughSystem 2.0. They let you dock and release boxes with one hand, and that’s not marketing fluff—I’ve stacked and unstacked this XL with a meter pouch in one hand and the box in the other. The caveat: those side latches are plastic. They’ve held up fine, but they don’t inspire the same “forever” confidence as the front metal latches. I treat them with respect, especially when the stack is loaded.

The lid opens just past 90 degrees and uses a hinge with firm detents. You’ll hear and feel it as you swing the lid—there’s a ratcheting sensation that’s normal. I’d prefer a wider opening arc or a stay to keep it planted on uneven ground; as it is, on sloped surfaces the lid can drift toward closed. It’s not a deal-breaker, but it’s something you learn to manage with where you set the box.

Handles are excellent. There’s a suitcase-style top handle and two broad side handles that fold flat. With a heavy load, that top handle doesn’t dig into the hand, and the side handles make two-person carries straightforward.

One minor nit: some trim pieces at the lower front corners on mine needed a firm seat out of the box. They’ve stayed put since. Functionally inconsequential, but worth checking when you unbox.

Size, capacity, and what actually fits

On paper, this is a 22-inch XL footprint with a 123-pound load rating. In practice, it’s a deep, wide cavity that shines for bulky tools or a stack of organized trays. I’ve used it in two primary modes:

• Big-tool mode: A compact cordless compressor fits—but only oriented face-down—and it’s snug. That tells you the usable footprint is generous but not cavernous; the lid ribs and interior tapers occupy a bit of space. Framing nailers, circular saws with batteries, or a bundle of impact drivers and batteries fit comfortably, especially if you pull the tray.

• Organizer mode: The included removable tray is handy for hand tools, testers, or fasteners you want immediately accessible. If you go further with optional ToughSystem trays or foam, the box becomes an effective top-down workstation. I’ve used a two-deep-tray setup with Kaizen foam to cradle impact wrenches and chargers, with a shallow tray riding on top for bits and PPE. The tradeoff is obvious—trays and foam consume volume—so if you’re trying to house one very large tool, leave them out.

The interior walls are fairly straight, which makes custom foam inserts efficient, and the lip height gives you a good margin for tall items without the lid fighting to close.

Stacking and compatibility

In a ToughSystem 2.0 stack, this XL box is a workhorse foundation or a mid-stack bin you can still access quickly thanks to the auto-latches. The side latch action is genuinely one-handable. I frequently stage it on a rolling 2.0 base and clip medium and small boxes on top—click, click, done.

Backward compatibility is solid for core boxes. I’ve stacked 2.0 on older ToughSystem 1.0 units and vice versa without drama, but it’s not universal for every legacy accessory. A few specialty tops and power modules don’t interface perfectly with the 2.0 lid geometry. If you rely on niche Gen 1 accessories to latch to the lid, test your specific combination before you commit to reorganizing your whole stack.

Because this XL has no wheels, I treat it as a stack element rather than a solo hauler for long distances. It’s fantastic parked on a rolling base; less so if you plan to carry 90 pounds of gear by hand across a site.

Weather resistance and the real IP65 story

An IP65 rating means dust-tight and protected against low-pressure water jets. The perimeter gasket on this box is robust, and the seal is confident. Tossed in the back of a truck in a storm, it’s kept contents dry.

Two practical notes:

• Water in the lid: The lid has channels and ribs that can collect water. If you open it upright while those channels are filled, water can dump into the box. My routine in the rain is simple—tilt the box back slightly and crack the lid to let water run off, then open fully. Keep a towel in the stack and it’s a non-issue.

• Gasket suction: After temperature swings or altitude changes, the seal can create a bit of vacuum. If the lid feels unusually stuck after transport, give it a moment and lift from a corner to break the seal. It’s the cost of a good gasket, not a defect.

Ergonomics and everyday use

This XL box is at its best when it’s doing two jobs at once: transporting bulky gear and acting as a stable base for a working stack. The large handles make truck-to-cart transfers easy. The front metal latches are quick; I can pop the lid with one gloved hand and fish out the tray for small items without rearranging the stack.

Because there’s no integrated lock point on this model, jobsite security relies on your environment and how you store the stack. If lockability is a must-have for you, that’s a limitation to consider, especially if this is your floor box in a shared space.

Durability

After real use—rain, dust, and plenty of loading—the shell shows the right kind of scars without compromising structure. The metal latches are still crisp. The side latches are intact and reliable but I don’t abuse them; I guide the stack as I clip and unclip, rather than yanking. For most pros and serious DIYers, that’s a fair trade for the convenience of one-hand stacking.

The lifetime limited warranty is reassuring, but I haven’t needed it.

Who it’s for

• Trades who move bulky tools and want those tools protected and stackable with the rest of a ToughSystem 2.0 kit.

• Service techs and installers who prefer a top-down workstation: trays on top for the small stuff, bigger tools below.

• Photographers, makers, and field users outside of construction who need dust and rain resistance and don’t mind the industrial look.

It’s less ideal if you want wheels built into every box, if you need a lid that stays open at a wide angle, or if your workflow depends on specialized Gen 1 accessories interfacing with the lid.

Pros

• Stout polypropylene shell with excellent metal front latches

• IP65 gasketed lid keeps out dust and rain

• Auto-connect side latches enable true one-hand stacking

• Generous capacity for bulky tools; straight walls play well with foam

• Comfortable top and side handles for heavy carries

• Backward compatible with most ToughSystem 1.0 boxes

Cons

• Lid opens only slightly past 90 degrees and can drift closed on uneven ground

• Side stacking latches are plastic; treat with care under heavy stacks

• No integrated padlock point on this model

• Lid channels can dump water inside if you open it upright when wet

• A few legacy accessories don’t mate cleanly with the 2.0 lid

Recommendation

I recommend the ToughSystem 2.0 XL box to anyone already invested in ToughSystem or looking for a durable, rain-ready, high-capacity bin to anchor a modular stack. It’s strongest where it counts—structural integrity, weather resistance, and fast, one-hand stacking—and its capacity is legitimately useful for oversized tools or a tray-and-foam buildout.

The compromises are manageable. Be mindful opening a wet lid, plan for no built-in lock, and don’t expect the lid to stay wide open on a slope. If you can live with those, this XL box is a reliable, hard-working piece of kit that earns its space in the truck and on the cart.