DeWalt ToughSystem Van Racking Brackets

Why I switched to folding brackets

I’ve been refining my van setup around DeWalt’s ToughSystem for years, and my biggest pain point has always been aisle space. Fixed shelves and arms are fast, but they’re shin bruisers and they eat into room I need for lumber, a hand truck, or just moving around. That’s what sent me looking for a folding option, and these brackets have been riding with me for several weeks across job sites, potholes, and highway miles.

Design and build

The brackets are compact, ribbed, and lightweight, with a reinforced plastic build that’s tougher than it looks. Each pair is rated for 44 lb, which is squarely in the “light-duty” category for van storage. They don’t pretend to be heavy steel arms; the trade-off is that they fold flat when not in use, are easy to reconfigure, and don’t add much weight to the rack.

Folded down, the arms give you a modest shelf depth that supports the footprint of standard ToughSystem boxes. Folded up, they tuck nearly flush to the rack, which makes a huge difference in a narrow cargo bay. The hinge action on mine is positive without being sticky—there’s a clear “home” position up and down—but it isn’t a locking hinge. That’s fine in practice, but worth knowing: they fold, they don’t latch.

Fit and finish are on-brand: clean molding, consistent edges, and no burrs. After a few weeks of use I’m seeing scuffs where cases land, but no cracking or whitening in the plastic.

Installation and setup

I mounted the brackets on both the High and Low ToughSystem van racking uprights to see how they behave in different layouts. The slotted mounting points give you enough play to fine-tune height and keep pairs truly level—important if you want boxes to sit without rocking.

One thing to plan for: my set did not include mounting hardware. I provided my own fasteners appropriate to the rack uprights. That turned out to be a non-issue once I was prepared for it, but it’s something to factor into your install day. A couple of tips from my install:

• Use washers against the plastic to spread the load.
• Snug hardware firmly, but don’t crank down—over-tightening on plastic components is a shortcut to stress marks.
• Set your first pair using a box as a physical gauge, then mark and measure subsequent pairs off that baseline.

If you’re considering these for a cart or carrier rather than the van racks, expect to do some adapting and again, source your own hardware. These are designed for the van racking system first.

Day-to-day use

In daily use, the fold-away function earns its keep. I can swing a pair down, drop a box, and head out. When I need the aisle, the arms flip back up and disappear. That constant reclaiming of space adds up during a busy day.

Loading and unloading is a touch different from fixed arms. Because these sit flush when folded, you’re unfolding, aligning, and then placing the box, which is slightly more fiddly if you’re doing it one-handed. After a week of muscle memory, I wasn’t thinking about it, but fixed arms are still a hair faster for rapid-fire in-and-out.

Once loaded, ToughSystem boxes sit squarely. There’s a bit of compliance in the plastic arms under weight—more of a gentle give than a sag—and I didn’t hear any alarming creaks or feel instability. Over speed humps and rough roads, the boxes stayed put, but I always recommend strapping or otherwise retaining anything in a moving vehicle. The brackets support; they don’t lock.

Noise-wise, the brackets are quiet. I didn’t notice hinge rattle, even on washboard side streets. If you’re sensitive to van noises, a small strip of tape on the contact point where the folded arm meets the upright will take out any potential chatter.

Load capacity and limits

That 44 lb per pair rating is realistic for the design. I tested with a DS box full of fasteners and a compact router kit, which puts you near that mark. The brackets held fine, but you can feel the margin get thinner as you approach the limit—especially with dynamic loads while driving. My rule of thumb: keep single-pair loads in the 25–35 lb range for daily use. If your boxes routinely exceed that, either stack them on the floor, add a second support point, or look at heavier, fixed metal arms.

Cold-weather performance was better than I expected. On a frosty morning, the hinges still flipped smoothly and the plastic didn’t get brittle or squeaky. I still avoid dropping heavy cases onto plastic hardware when it’s below freezing; set them rather than slam them.

Compatibility

These brackets have been happy with every ToughSystem box I tried, including toolboxes, organizers, and the deeper cases. The arm depth is adequate to catch the base and keep weight centered. Wider specialty pieces may overhang a touch, but as long as you center the load, it’s a non-issue.

They play nicely with both High and Low van racking configurations. On the High rack, I staggered pairs to create a stepped layout for quick access; on the Low rack, I ran them level to build a shallow shelf row. In both setups, the fold-away advantage was the same: cleaner aisles and fewer snags.

What I’d change

• Include hardware: Expecting installers to source their own fasteners slows setup and invites mismatches. Even a basic hardware pack would make first-time installation smoother.
• Faster one-hand deployment: A slightly stronger detent or a small tab to grab would make flipping them down while holding a case easier.
• Higher rating option: A metal-reinforced version at a higher load rating would open this design to heavier kit without losing the folding benefit.

None of these are deal-breakers, but they’re the rough edges I noticed in everyday use.

Durability and warranty

So far, the plastic has shrugged off normal wear—no cracks, no loose hinges. The ribbing and overall geometry carry the load well for the intended duty. The lifetime limited warranty adds confidence, but as always, keep receipts and photos of your install in case you ever need support.

Value

These aren’t the cheapest way to store boxes in a van, and they’re not trying to be. What you’re paying for is a flexible, modular add-on that recovers space when you don’t need it and supports light loads when you do. If your van workflow benefits from fold-away components, these make sense. If you rarely need to reclaim aisle space and you’re moving heavy boxes, fixed metal shelves will be faster and stronger.

Who they’re for

• Tradespeople already invested in ToughSystem who want modular, fold-away support for light loads.
• Vans where aisle width is at a premium and snag points are a real problem.
• Anyone who frequently reconfigures their storage layout depending on the job.

Who should look elsewhere:

• Users with consistently heavy boxes or bulky equipment that push past light-duty loads.
• Setups where maximum speed of loading/unloading with one hand is the top priority.

Recommendation

I recommend these brackets for ToughSystem users who value space efficiency and modularity over raw load capacity. They fold flat, install cleanly on the ToughSystem van racks, and carry light loads without fuss. Be prepared to supply your own mounting hardware and accept a small learning curve compared with fixed arms. If your day-to-day kit fits within the 44 lb per pair rating and you want a cleaner, safer aisle, these are a smart, low-profile upgrade. If you need to park heavy boxes on arms or prioritize one-handed, rapid-fire loading all day long, stick with fixed metal supports instead.