DeWalt ToughSystem 2.0 toolbox

Overview

I put the ToughSystem 2.0 box through a month of jobsite and truck use, stacking it under, over, and alongside other ToughSystem modules, and building out a battery-and-charger kit I could move in one hand. This small-format box promises one-hand auto-latching, IP65 dust/water resistance, and a 110 lb load rating in a compact, impact-resistant shell. In practice, it’s a genuinely useful, durable organizer with a few quirks to know about—especially if you work outside in wet conditions or rely on fast access when it’s stacked on a rolling base.

Build and design

This box leans into the 2.0 line’s sturdier construction. The shell is thick plastic that shrugs off the usual bumps and drops, and the two-piece metal front latches feel secure without needing a two-handed slam to close. The auto-connect side latches are the standout: they hook and lock with a downward push so you can align and connect to another module with one hand, then release with a simple squeeze. That one-hand operation is a real timesaver on stairs and in tight spaces.

At 21.255 x 14.625 x 7.02 inches and 6.6 lb empty, it’s compact enough to carry with a full load without turning into a deadlift. DeWalt rates the box at 110 lb capacity. I loaded it to roughly 80 lb with a mix of batteries, a charger, and hand tools and didn’t see flex in the lid or distortion in the latches. The box is part of the ToughSystem ecosystem and plays well with both 2.0 and earlier ToughSystem modules.

One caveat: there’s no padlock hasp. If you need true lockable security, you’ll have to look elsewhere in the lineup or add a separate locking mechanism upstream (locking vehicle/tool cabinet).

Capacity and organization

Inside, you get two large organizer cups with removable dividers. In a box this size, those cups are surprisingly handy for batteries, small parts, or odd-shaped electronics you don’t want sliding around. I built a mobile battery kit in mine that comfortably housed:
- Two DeWalt chargers (one 6A, one 4A)
- Multiple 20V and FlexVolt batteries
- A multimeter and calipers in a soft pouch

If you work with delicate gear or want repeatable layouts, this footprint works well with the deep foam inserts DeWalt offers for the 2.0 system. Cutting foam to your kit is a great way to maximize space while preventing rattle and impact shock.

Compared with the original ToughSystem small box, the 2.0 version nets more usable space thanks to the refined shell geometry. It’s not dramatically larger on paper, but those small gains in internal volume make a difference when you’re trying to fit a second charger or keep bulky items upright.

On the jobsite

In day-to-day use, the ToughSystem box shines when you’re building out task-specific kits—batteries and chargers, testing tools, layout tools, or a fastener assortment. It’s also a solid grab-and-go box for field work in dusty environments. The form factor slides neatly onto shelves and into truck compartments, and the flat top makes a good stack base for another small or compact organizer.

I spent a few days using it as a range/photography case as well, and the box lends itself nicely to non-trades uses. The high-impact shell and gasketed lid add confidence when you’re carrying electronics or optics.

Stacking and connectivity

The auto-connect latches are the 2.0 system’s secret sauce. They let you drop this box onto another module and hear/feel it engage without fiddling with hooks. It’s backward compatible too: stacking to an older ToughSystem module works fine, though you lose the one-handed “auto” convenience on the older box.

One thing to note: when this box is stacked on the ToughSystem rolling base, the lid doesn’t open fully. The handle/structure of the rolling base interferes and stops the lid short. It’s not a deal-breaker, but be prepared to unstack or pull the box forward if you need a full-open lid on the cart.

Weather resistance

This box carries an IP65 rating, which means dust-tight and resistant to water jets from any direction. In real terms, it keeps out jobsite dust and shrugs off splash, spray, and short bouts of light rain. The gasket is substantial, and as long as the latches are fully seated and the seal is clean, you get reliable protection.

Two practical notes from my time in wet and humid conditions:
- Don’t treat IP65 like submersion-proof. Sitting in standing water or hours of driving rain can overwhelm any gasketed lid, especially if debris is in the seal.
- Humidity is sneaky. A sealed box can trap moist air, leading to condensation on cool mornings. Toss a silica gel pack inside if you store the box in a truck bed or unconditioned space. It’s a simple, cheap way to keep metal tools and battery contacts dry.

I left the box in an overnight drizzle on a tailgate and saw no ingress. After a full day of on-and-off rain with the box exposed, I did find a couple of small droplets clinging inside the rim—likely from opening it while wet. Wiping the gasket and latching it cleanly eliminated that on subsequent days.

Durability and maintenance

The shell and latches feel built for abuse. I’ve knocked it off a bench and bounced it in a truck bed without issue. That said, like any plastic system, alignment matters when you’re stacking: if you force the side latch onto a misaligned box, you can stress the latch bracket. The auto-connect feature helps here, but it pays to set the box squarely before locking it down.

Keep the gasket clean. A quick swipe with a rag does wonders for maintaining the seal. If you routinely work with fine dust or mud, that little bit of upkeep makes the IP65 rating more than just a spec sheet note.

The box comes with a lifetime limited warranty, which offers peace of mind for structural failures. As with all warranties, that’s not a free pass for wear and tear, but it’s good to have.

Ergonomics

Carry comfort is good for the size and weight class. The handle is balanced over the center of mass when the organizer cups are filled evenly, and the footprint keeps the box close to your body so it doesn’t swing into door frames. The metal front latches are glove-friendly and don’t require excessive force. The lack of a lock hasp does mean there’s one fewer thing protruding from the lid, which keeps snag points down.

What could be better

• Lockability: I’d like a padlock eye. For many users, visual deterrence matters as much as actual security.
• Lid clearance on the rolling base: Full-open access would be ideal when the box is mounted on the cart.
• Moisture management: The IP65 seal is solid, but if you regularly leave boxes outdoors, consider adding desiccant and making gasket cleaning part of your routine.

None of these are deal-breakers, but they’re worth knowing up front.

Who is it for?

• Tradespeople building task-specific kits who want a compact, rugged box that integrates with a larger modular system.
• DIYers and hobbyists who want a durable organizer for electronics, range gear, camera equipment, or riding kits.
• Anyone already invested in ToughSystem who needs a small-format module with 2.0 auto-latching convenience and improved internal space.

Recommendation

I recommend the ToughSystem 2.0 box for most users who need a compact, stackable, and weather-resistant organizer that plays nicely with the broader ToughSystem ecosystem. It’s sturdy, the metal latches and one-hand side latches are genuinely useful, and the internal cups with dividers make it easy to keep small gear in check. The IP65 rating holds up well for jobsite dust and intermittent wet, as long as you keep the gasket clean and manage humidity with a desiccant. The lack of a lock hasp and the lid’s limited opening when mounted on the rolling base are drawbacks, but not deal-breakers. If lockable security is a must, or you routinely leave gear exposed in heavy, sustained rain, look for a box with a lockable hasp or consider protective measures. For everyone else—especially those already on ToughSystem—it’s a smart, durable addition that earns its spot in the stack.