DeWalt 20V MAX XR POWERSTACK 5Ah Battery Kit

Why I reached for the PowerStack 5Ah kit

I’ve been swapping batteries across a busy 20V MAX lineup for years, and a 5.0 Ah pack is my daily driver size for most tasks. The PowerStack 5Ah kit pairs that familiar capacity with DeWalt’s pouch‑cell design and a single‑port charger. After several weeks using it on everything from an impact driver to a grinder and compact circular saw, I’ve formed a clear picture of where it shines, where it’s just “fine,” and who should consider paying the premium.

Design, size, and durability

The PowerStack 5.0 Ah battery is compact for its class. At about 5.2 x 3.3 x 2.2 inches and roughly 1.5 lb, it feels shorter and tighter than the brick-like footprint of older hard‑can packs. That smaller profile matters more than you’d think: the pack tucks into confined spaces better, it doesn’t snag when I’m reaching between studs, and it slightly improves the balance on compact tools. On a trim router and oscillating multi‑tool, the tool felt less tail‑heavy and easier to control on finesse cuts.

The overmolded base is genuinely useful. I’ve set this pack down on concrete, tossed it in a job box, and knocked it off a tailgate once by accident. The rubberized skid and reinforced shell absorbed those bumps without drama. It stands upright securely and doesn’t chatter around on metal surfaces the way smooth‑shell packs do.

A 3‑LED state‑of‑charge indicator sits on the rear. It’s easy to thumb with gloves on and visible in bright light. Three LEDs aren’t surgical‑grade precision—under heavy load the last bar can disappear quickly—but it’s accurate enough to plan a swap between tasks. I’d still love a four‑bar gauge, but I didn’t feel shortchanged.

Charger and charge time

The included single‑port charger (reported as the DCB1104) brought the pack from flat to full right around the 90‑minute mark in my tests. That’s in line with expectations for a 5.0 Ah pack on a 4‑amp class charger. The fan noise is modest, thermal behavior was predictable, and it recovered well after hot runs with a grinder—no extended cool‑down delays before it would accept a charge. If you have multi‑bay chargers on the bench, this won’t replace them, but as a kit charger it’s a solid, compact unit.

Performance on tools

DeWalt positions the pouch‑cell construction as a way to deliver higher power density and better cycle life versus the older 5.0 Ah hard‑can pack. Marketing aside, here’s what I actually felt:

• Impact driver and compact hammer drill: Driving structural screws and 3/16–1/4 inch Tapcons into cured slab, the tools held peak speed longer and were less prone to that momentary bog you get right before a battery triggers a voltage sag under load. It’s not night‑and‑day, but the consistency is noticeable—especially at the last third of the charge. If you’re used to your tool feeling “fresh” for the first bar and then tapering off, this pack keeps it on‑song a bit longer.

• 6‑1/2 inch circular saw and jigsaw: Ripping 3/4 inch ply and crosscutting 2x, I saw a small but real bump in cut speed, particularly in continuous cuts. The saw maintained RPM better at mid‑charge than with my older 5Ah brick. On the jigsaw with a long metal cut, it avoided the stutter I sometimes see when a battery gets warm and droops.

• Angle grinder (the acid test): This is where the PowerStack earns its keep. Grinding and light flap‑disc work, I got fewer thermal cutbacks and fewer stall‑recoveries. It feels like the pack can deliver higher sustained current bursts without getting flustered. If you run a grinder or compact SDS‑Plus rotary hammer regularly, you’ll appreciate this behavior.

• Oscillating multi‑tool and finish nailer: No practical difference beyond the nicer balance. These tools don’t stress a 5Ah pack much, so the PowerStack’s advantages are harder to detect.

What about runtime? On moderate‑draw tasks (driving screws, trim carpentry, oscillating multi‑tool work), runtime was essentially on par with a good condition 5.0 Ah cylindrical‑cell pack. In heavy‑draw scenarios (grinding, long rips), I didn’t necessarily get more total minutes, but I did get “better minutes”—the tool stayed strong deeper into the discharge rather than feeling an early drop in performance. Said differently: the energy content feels the same; the way it’s delivered is improved.

Thermally, the pack finished hot less often and cooled a touch quicker on the bench. Pouch cells can, in theory, shed heat more efficiently due to flatter geometry, and my usage lines up with that: fewer thermal‑induced slowdowns and faster readiness to recharge after a punishing run.

Ergonomics and balance

On compact tools, the reduced height makes a difference. The multi‑tool was easier to feather, the trim router felt less tippy, and the impact driver fit into cabinet carcasses where a taller pack would have kissed the edge. Weight is comparable to a standard 5Ah, but the mass feels lower and closer to the grip, which helps precision work.

Compatibility and warranty

It’s fully compatible with 20V MAX tools and chargers and carries DeWalt’s 3‑year limited warranty, 1‑year free service, and 90‑day satisfaction guarantee. I cycled it across old and new tools without a hiccup. If you’re already invested in the line, it drops right in.

The fine print and trade‑offs

• Price premium: You’re paying more than a conventional 5Ah. If your work doesn’t push batteries hard—light carpentry, punch‑list fixes, shop assembly—the tangible benefits may not justify the premium.

• Single battery kit: It’s a starter bundle with one battery and one charger. Pros who like to hot‑swap might prefer a two‑pack, or plan to mix this with existing packs.

• Indicator resolution: Three LEDs are fine, but not especially granular if you like precise readouts before climbing a ladder.

• Gains vary by tool: The more you lean on high‑draw tools, the more you’ll notice the voltage stability and thermal behavior. For low‑draw tools, the advantage is mostly about size and balance rather than speed or runtime.

Who benefits most

• Remodelers and carpenters who bounce between tight spaces and high‑demand cuts. The compact footprint plus better load handling is a nice combo.

• Metalworkers and MRO techs running compact grinders or rotary hammers on cordless platforms. Fewer stalls and steadier power make real productivity differences.

• Anyone chasing the best performance from premium XR tools. If you already own high‑output 20V MAX tools, this battery lets them show off a bit more of what they can do.

If you mainly run radios, lights, or low‑draw tools, you’ll see little beyond nicer ergonomics. Pair those with a 2.0–3.0 Ah compact or a value‑priced 5Ah, and you’re still in good shape.

Value and longevity

I can’t speak to multi‑year lifespan yet, but pouch‑cell chemistry is typically kinder to high‑rate cycles, and the pack’s cooler running should bode well for longevity. As always, battery life comes down to heat, charging habits, and environment. The included charger is reasonable on all fronts, and I appreciated that the pack would accept a recharge promptly after hot use without extended “cool‑down purgatory.”

As a kit, it’s a clean way to add one high‑performance pack and another compatible charger to a jobsite or home shop. If you already own multiple chargers, the value calculation shifts toward just buying the battery loose when on promo.

Recommendation

I recommend the PowerStack 5Ah kit for users who regularly push their cordless tools—think grinders, circular saws, compact rotary hammers, or long sessions with an impact driver. You’ll feel steadier power under load, fewer stalls, and a meaningful ergonomic improvement thanks to the compact form factor. If your tool use is lighter duty or intermittent, the premium over a standard 5.0 Ah pack is harder to justify; you won’t see much more runtime, and the performance gains will be subtle.

In short: for performance‑minded users in the 20V MAX ecosystem, this kit earns its keep. For budget‑minded users doing lighter work, stick with conventional packs and upgrade only if the compact size or steadier under‑load behavior solves a specific problem for you.