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メナHey there, I’m Mena (@menachite), a hybrid engineer who handles both mechanical and electrical work.
It’s been about a year since I picked up the original DEWALT ToughSystem.
The original ToughSystem has more than proven itself useful, so I decided to bring in a toolbox with some new features.
DEWALT had quietly released a new lineup called ToughSystem 2.0.
It had actually existed for a while, but it wasn’t sold in Japan yet so I skipped it — looks like that’s now finally changed globally, and it’s become widely available.
This time I wanted a toolbox with drawers, so I picked up the ToughSystem 2.0 2-drawer chest. While I was at it, I figured I’d dig into the questions everyone has: is ToughSystem 2.0 actually compatible with the original ToughSystem? What’s actually different?
Cutting to the conclusion: yes, it’s a genuine upgrade over the previous generation and a solid toolbox. But if you’re asking whether owners of the original ToughSystem should proactively upgrade — the answer is no. In some respects the original is actually better, and there are a few points where the new series is a step down. I’ll break all of that down below.
DEWALT’s ToughSystem 2.0 lineup — including the original generation — has grown into a fairly sprawling, confusing catalog, so I’ll review the ToughSystem 2.0 products one at a time.
I’ve also put together a spec comparison table between the original ToughSystem and ToughSystem 2.0, so check that out too.
ToughSystem 2.0 Product Spec Rundown
Small Toolbox
This is the smallest toolbox in the ToughSystem lineup.
Compared to the original, it’s about 200g heavier and slightly larger overall. Interior dimensions are also larger, so overall capacity has genuinely improved.
As for the internals: the original had storage space built into the underside of the lid. That space has been removed on ToughSystem 2.0, replaced instead by a small removable inner tray.
Whether that’s a plus or minus really comes down to what you need — if you want that lid-back storage, go with the original series; if you’d rather have a proper inner tray, ToughSystem 2.0 is probably the better fit.
Medium Toolbox
The medium box is a genuinely convenient size to carry around. Like the small box, capacity is up over the original, and the overall size is a bit bigger too.
I keep an entire Makita cordless driver case plus a full parts case inside, and there’s still room left over for extension cords and the like.
The removable inner tray is handy. On the original ToughSystem, the tray ran the full width of the box, but this one comes with a tray roughly half that width — which I actually find more convenient when you’re grabbing it and heading out the door. It also means the tray doesn’t get in the way when you’re storing taller tools.
The old full-width tray was great for carrying larger tools, but it got in the way when working in tighter spaces — this new format fixes that downside.
Large Toolbox
Contents-wise, this is basically the same story as the medium box.
But one thing worth calling out: it’s actually lighter than the original ToughSystem’s large box.
My guess is some clever shape engineering let them keep the same durability while cutting weight.
It’s deep enough to fit an entire Makita cordless drill case inside.
It also comes with the same style of tray.
By the way, TSTAK recently released the ToughCase — and this large box is roomy enough to swallow even the biggest size of that.
2-Drawer Chest
The 2-drawer chest had been discontinued for ages on the original ToughSystem, so when it came back for ToughSystem 2.0, I jumped on it immediately. This thing is great.
The drawers slide impressively smooth and click shut with real reassurance — they won’t pop open on you. Classic DEWALT solid build quality. Both drawers are roughly 100mm deep, which is deep enough to fit cordless tools inside.
Originally, the whole reason I wanted this drawer unit was to fit a Kohnan-brand parts case inside… which, unfortunately, didn’t work out. (sigh)
The interior dimensions should have fit it perfectly, but the drawer handle sticks in slightly from the inside, which got in the way.
I gave up on that particular case and now use the top drawer for consumables and the bottom drawer for storing drill and bit boxes.
The drawers have rubber gaskets built in, so they’re properly weatherproofed. That weatherproofing runs across the entire lineup, and honestly, it says a lot about how seriously DEWALT takes weather resistance.
3-Drawer Chest
A 3-drawer version is also available in the ToughSystem 2.0 lineup, offering an extra tier of drawer storage if you need more organized capacity than the 2-drawer chest provides.
Organizer
The full-width organizer rounds out the ToughSystem 2.0 lineup with a dedicated small-parts storage option — useful for screws, bits, and other small hardware you want to keep sorted and stacked with the rest of your ToughSystem gear.
Half-Width Organizer
There’s also a half-width organizer in the ToughSystem 2.0 lineup, which pairs nicely if you want a smaller dedicated small-parts box without committing to the full-width unit.
Tool Bag
There’s enough to say about the ToughSystem 2.0 tool bag that I wrote up a separate, dedicated review article for it — if you’re curious, it’s worth checking out.
Half-Size Tool Bag
Same story here — I cover the half-size tool bag in that dedicated review article as well, alongside the full-size version.
What Changed Across the Board Going from ToughSystem to ToughSystem 2.0
Here’s a rundown of the changes that are common across the whole lineup going from the original ToughSystem to ToughSystem 2.0. A few of them are changes you wouldn’t expect, so they’re worth knowing about.
The Lock Mechanism Changed
The locking mechanism switched from the old metal buckle style to a wire-lock style.
My first thought was, “is this just a cost-cutting move?” But after actually using it, it locks down firmly and holds just as strong as the old buckle.
This is really the headline feature that determines whether ToughSystem 2.0 is worth it for you.
With the original, you had to manually lock each side of the toolbox individually, which took a bit of time.
With ToughSystem 2.0, instead of locking each side separately, simply setting one box on top of another locks it in place automatically. To release it, you just press the latch by hand and it stays released, so removal is easy too.
This is one of those things you can only really appreciate if you’ve used the original — attaching and detaching boxes used to be genuinely stiff and, honestly, a low-key source of stress. Not having to deal with that anymore is a bigger deal than it sounds. ToughSystem 2.0 really is easier and more relaxed to use.
The Overall Finish Feels More Premium
The build quality feels like a step up too. The original had that raw, as-molded engineering-plastic look and feel to it — which honestly had its own rugged American charm that I liked.
ToughSystem 2.0 has a matte exterior finish that reads as translucent and genuinely refined. When you stack a different generation next to it, the difference in texture really jumps out.
The original leans slightly dry and a bit scratchy in feel, while the 2.0 has a glossier, more premium texture. Personally, that was a welcome upgrade.
The System Carrier Anti-Theft Lock Was Removed
The ToughSystem lineup includes an accessory called the System Carrier (see our dedicated article on that for details). On the original ToughSystem, the toolboxes had a locking mechanism specifically for the System Carrier, letting you lock the toolbox to the carrier itself.
In other words, unless someone stole the entire carrier setup, they couldn’t walk off with just the toolbox.
It’s a genuine letdown that this System Carrier lock mechanism was dropped on ToughSystem 2.0.
The Leak Valve Was Removed — Replaced by a Latch That Connects to the Half-Size Box
The ToughSystem lineup seals the lid edge with rubber gaskets for weatherproofing, which means if you seal it closed and then travel somewhere with a different air pressure, the lid can end up stuck shut.
The original ToughSystem had a leak valve to relieve that pressure — twist it and it lets the trapped air out.
On ToughSystem 2.0, that same spot has been turned into a latch that lets you dock a half-size toolbox onto it instead.
Honestly, in all my time using ToughSystem boxes, I’ve never once actually used the leak valve, so unless you’re hauling gear up mountains or across international flights regularly, you’re unlikely to miss this feature much.
Since there’s now a dedicated organizer for the half-size toolbox in the same series, this latch arguably makes the box more useful overall.
By the way, even with this latch flipped up, you can still connect the box to a standard-size toolbox just fine.
Compatibility Between the Original ToughSystem and ToughSystem 2.0
For the most part, the original ToughSystem and ToughSystem 2.0 are compatible with each other.
That said, there are a few specific points where the original ToughSystem isn’t fully compatible, so let me walk through those.
The Original ToughSystem Can’t Take the Half-Size Toolbox Attachment
ToughSystem 2.0 has a half-size organizer available.
Mounting it requires flipping up the center locking latch.
On the original ToughSystem, that same spot is occupied by the leak valve, so this attachment isn’t possible.
The System Carrier Works With Both Generations
The System Carrier mounts by hooking onto the handles on both sides of a toolbox, and since the handle shape hasn’t changed meaningfully between generations, it mounts without any issues either way.
Boxes From Both Generations Can Be Stacked and Connected — But There’s a Catch
Docking and connecting toolboxes works fine between old and new generations.
It works with either one on top, so if you already own original-generation ToughSystem boxes, putting a ToughSystem 2.0 box on the bottom actually makes the original box on top easier to grab and use — a genuinely nice combo.
There is one issue: when you put a ToughSystem 2.0 box on the bottom, the height of the new latch mechanism leaves a small gap against the original ToughSystem box sitting on top.
You can still lift it as a stack, but it flexes a bit when the load is uneven.
It’s a minor letdown — feels like something that should’ve been easy enough to design around.
Summary
ToughSystem 2.0 genuinely delivers more storage capacity and a real step up in performance.
The 2-drawer chest coming back into the lineup especially was something every DEWALT loyalist had been waiting for!
That said, personally, losing the System Carrier anti-theft lock stung a bit.
That alone is honestly reason enough for some people to stick with the original — ToughSystem gear tends to walk off if you’re not careful.
I’d genuinely love it if DEWALT sold that lock mechanism as an add-on accessory, even after the fact.
On its own, though, this is a genuinely solid toolbox once you factor in the expandability and the improved build quality — worth checking out if you’re on the fence.