After testing Dewalt’s ToughSystem DXL tool box system over the past year, I finally made up my mind – it is reasonably compromised.
In no uncertain terms, this is a specialty product – a modular or semi-customizable portable workstation solution.
This is somewhat long post that can be summed into a single sentence: I love the idea of Dewalt ToughSystem DXL, and while impressively designed and well built, its real-world utility wasn’t at all what I expected or hoped for.
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Overall, the system is not tailored towards general purpose storage needs or wants, and everything that follows is an attempt to explain, forgive, and provide context to the disagreement between still loving the idea while also greatly disliking actual using it.
Home Depot stores have it on clearance. I’ve heard some call the Dewalt DXL system a “failure.” It’s not, it just requires a little understanding.
I tested the samples Dewalt provided – thank you! – in various ways. Most of the time, I set it up as shown here, minus the side rail accessories.
The 5pc set ships with the dolly, two 1-drawer tool boxes, one 2-drawer tool box, and the work top with side handle.
Let’s talk about the compromises first.
There’s a lot of plastic. This cannot be avoided simply because of how large the drawers are. Still, you need to be careful about how you load the drawers and how you distribute the weight.
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It’s heavy. I can move the individual tool boxes around by myself when empty, but not when loaded.
While mobile, it’s a chore to roll over uneven ground and maneuver on smooth flooring.
Finally, if you’re buying it for yourself or a small business, it’s pricey. But is it? If you compare the size and capacity to other modular plastic tool box systems, Dewalt ToughSystem DXL is relatively on-par price-wise.
I recently donated my test sample stack. Before that, I donated the rest of the ToughSystem tool boxes and drawers that I had purchased.
Dewalt ToughSystem drawers and tool boxes are easy to recommend and justify. But the DXL tool boxes?
It was very difficult to make the most of the storage capacity. Longer-term, I would have made my own dividers or similar.
In the context of a portable workstation, all of these seem like reasonable compromises.
But for my own needs, I tried so hard to make the DXL system work, but couldn’t pass it along fast enough.
Dewalt’s supersized DXL modular tool box system is excellent for what it is, and I haven’t seen anything else like it.
If you look at it through that lens, it has compromises but they seem justifiable and workable.
As a modular tool box system, you don’t have a lot of configuration options. Yet?
This is the type of storage product that you should only consider with specific intent. For example, if you see it in stores or the product page and think “that’d be perfect for my needs,” it might be.
Personally, I really loved the idea of what I wanted it to be, and that proved to be a mistake.
I didn’t like mixing DXL components with smaller ToughSystem tool boxes or organizers.
Some people consider the cart to be suitable for ToughSystem tool boxes. I tried using it with just my standard-size drawer tool boxes, and it was incredibly inefficient compared to other systems.
I’m glad that Dewalt designed ToughSystem DXL components to be compatible with smaller ToughSystem tool boxes. Is it ideal? No. Workable? Maybe. I didn’t think so, but maybe others’ experiences will be different.
If I bought this for my own use at full price, I would be very disappointed. But I didn’t – Dewalt provided this to me for testing at no cost, and I recently gave it away in the same manner.
I have no personal investment in the DXL system, aside from 2 carts that I bought for use as dollies. And no, that didn’t work out well, I eventually harvested the casters and discarded the plastic bases.
Because I have no investment, other than optimism and excitement leading up to the review opportunity and testing period, I feel that I’ve been seeing it from a neutral stance.
It’s mobile, but not very portable – at least not hand-carryable unless you grab a buddy to help.
Dewalt ToughSystem DXL was designed to move, and it does that kind of well. I’m not impressed by its rolling resistance, but I also don’t know of any off the shelf workstation or cart that offers as much as you get here.
I’m sure you can tell that I ultimately didn’t like it. I think it was a poor fit for me.
If I were in the market for a jobsite utility cart, maybe that’s where DXL would excel.
When on sale, maybe that’s when some users can deal with a narrow mismatch to their needs or wants.
This all sounds overly negative when I read it back, and that’s not intentional. I am actually impressed with what Dewalt accomplished; it’s a huge deal that they engineered a large-format modular mostly-plastic tool box system that doesn’t buckle under modest weight.
The casters are excellent – two are fully locking and two can be locked into fixed position so that they don’t swivel.
I loved the construction, and the latching mechanisms were mostly trouble-free.
There aren’t any flaws in the design or engineering that I could easily find.
However, overall, it’s like putting together a sandwich that just doesn’t satisfy you.
The system is harmonious, but at the same time the details make it impractical.
I did not enjoy working out of the tool box. I had to make compromises as to what I was able to store inside the drawers.
I couldn’t fit a reciprocating saw in either deeper drawer without removing the dividers, which decreased its usefulness. This ultimately led me to appreciate the Makita MakTrak tool box system – see Makita MakTrak Tool Box is a Perfect Fit.
If I can’t fit what I need to fit, then I need alternatives.
Dewalt launched a novel system that offers something to the tool industry. Who exactly is it for? What types of work environments will it bring improvements or greater convenience to?
I can tell you all kinds of hypothetical ways I think it could be used. But when I tested the cart in such ways, there was no “yes, this is perfect” type of moment.
I think that Dewalt DXL is well-suited for businesses seeking very specific solutions.
Shown here is a Huot CNC tooling cart. The Dewalt DXL tool box system is more flexible, but it’s not a universal-type product.
I consider DXL to fit narrow user types and work environments. What types? Frankly, I cannot even guess.
You’ll know what you can use it for the moment you see it. Or not.
Just don’t make the mistake of treating this as a general purpose tool box system. It’s not.
Can I recommend it? Yes. Everything was well-made and brilliantly designed. Can I recommend it to you? No. Anyone I know? No.
I’m having trouble finding hypothetical situations where this is the perfect product solution, but I’m sure there are some.
So much is excellent about the Dewalt ToughSystem DXL tool box and workstation system.
Combine it all together, and I truly couldn’t make it work out.
What makes this all so difficult is that I also don’t think Dewalt did anything wrong. What would I do differently? What could be improved? I have no answers.
It was clear to me that a lot of work went into tuning everything, from the secure drawer latches to how the boxes stack and connect together. That’s not enough.
I hope you can understand how difficult of a review this has been. After thoroughly testing the DXL combo with different tools and supplies, here’s my final verdict:
Dewalt ToughSystem DXL is well constructed (for what it is), but be sure to only consider buying it with strict intent.
I think that the system can be improved with additional modular-components – such as an open bottom bin – but I’m not sure if or when Dewalt will be expanding upon the system. More configuration options could change everything.
Some people have been happy with their purchases. Would you be?
Buy it at Home Depot:
Dewalt 2-Drawer DXL Tool Box
Dewalt 1-Drawer DXL Tool Box
Dewalt DXL Work Top
Dewalt ToughSystem and DXL Cart
Dewalt DXL 4pc Combo Set – 1-drawer, 2-drawer, cart, worktop
Dewalt DXL 5pc Combo Set – (2)1-drawer, 2-drawer, cart, worktop
Goodie
It’s been written on these forums before, but I think these are not designed for the typical Home Depot crowd. This is a Grainger (or one of their competitors) style product. Maintenance folks working on large office complexes or in an industrial setting are, I believe, the correct audience for the DXL line. Something they can push to a location where they are working, and have everything organized for their standard workflow. It might also be useful for a specialized contractor (perhaps an AV or onsite construction company that will be located on their project for months or years. For these folks, it will almost never be taken apart or moved on a vehicle, unless it’s on a truck with a lift gate.
I used to see this type of work cart frequently being moved around a large, five sided office building that I used to work at.
MM
Bingo.
I currently have no use for DXL. However, I used to have a great one. I previously managed a materials lab at a major university. The lab was spread over multiple rooms in multiple buildings, and I often needed to transport tools, & calibration supplies between them. DXL would be perfect for that, much better than the commercial Rubbermaid carts I used. As you said these would not have been taken apart or put on a vehicle–I’d wheel them out of my office when needed, they would need to go on elevators and be moved outside between buildings, but that’s it. No lifting in and out of trucks, just rolled around on hard ground and in-and-out of elevators.
If I was still working that job I’d have bought DXL the moment I learned about it.
TomD
And in that market, the kind of Grainger or Uline product, their prices quite competitively and I think they could’ve been quite successful – but Home Depot floor is not where you market.
Stuart
Yes, and no. The shallow drawer was too small for a lot of the equipment we moved around, and the deep drawer inefficient.
It also wasn’t as easy to move around as other types of carts. It didn’t quite feel at home on rough pavement, and the same was true about my garage floor.
This would be a good indoors lab, factory, or MRO type of cart, maybe better if there were more customization options.
TomD
That’s the problem – the key feature is customizability and if what you sacrifice to get it is too much, it’ll never be worth it.
It’s like trying to use a drawer stack of Packout in the workshop – it will almost always lose to a metal cabinet of some sort (except in mobility which isn’t being used).
CMF
Always looking for new products to market, maybe Dewalt was thinking of bringing the more commercial carts you find at industrial suppliers to the home consumer. A bit smaller, less robust, and a little less than the commercial/industrial products, priced where a home consumer could take a shot at them, but in the end, it has not caught on?
Although Systainer, L Boxx and others were around, it was Dewalt’s ToughSystem started the boom we are in now.
TS may have had detractors when it came out thinking it would not catch on at those prices. Instead it did and everyone has a similar system.
They took a shot with TS and it was a winner, DXL has not caught on.
Stuart
ToughSystem 1.0 was good, and 2.0 better, and also Ridgid Pro Gear, but it was Packout that really accelerated adoption in the USA, and that led to the modern competitive environment.
will
So what makes the packout system better than the deaalt tough system? I haven’t seen the packout in person so dont know if they use the poly like TS or harder more rigid like the systainers. To me its hard to beat the tough system for strength,but maybe milwaukee was smart. None of the release a part here and there,nah they waited until they had a full system, is thst it or is it just the milwaukee name?
s
the big difference here is going to be the drawer size. packout has smaller overall dimensions.
where the dewalt dxl can fit a sawzall in a drawer, only the largest rolling packout drawer can fit a sawzall, diagonally across the space, if at all.
Stuart
Drawer size options, front-access connectivity and removal, single-width cart with floor brake.
Milwaukee built up their system through gradual expansion. Dewalt hasn’t shown much interest in expanding ToughSystem. That’s okay, but Packout currently offers a lot more breadth.
Levdidit
I got a couple and the wheels. I like the fact everything is stackable together with the old boxes. The wheels though could use some work, hard to move it.
I don’t like the price per drawer, few drawers per box. Although I like it over a metal drawer system that is to heavy to lift by myself. Could clear these out and move them. Also the small boxes sit in a different direction, so it’s hard to use the hanging attachment on the side. Might get one more box in the future to make that workable, but pricey, I guess we’ll see.
Ryan
We heavily make use of the Rubbermaid carts with the Knaack Cart Armour for our vehicle fabrication shop and our IT department uses them for lockable portable storage. They move easily and they work great as a work surface, storage box, and you can fit 3 of the TStak medium boxes on the bottom shelf. You can even hang Akrobins off the sides.
I think they are just a little more versatile for an industrial setting, especially if you laminate some 4x4s and drill a few dog holes to place it on top as a mini-bench.
Tdot77
Those Knaack Cart Armour setups are pretty cool addition to the Rubbermaid carts. First time hearing about them, & just checked them out out of curiosity. I don’t work in that kind of environment but they’re definitely perfect for securing stuff on those tough Rubbermaid cart seen in those industrial settings.
Robert
Stuart, if there was a dolly base option with really large wheels instead of the casters, so that it could be easily wheeled over uneven surfaces as a jobsite utility cart, would that change your verdict?
Kyle
A hypothetical on top of the already hypothetical use cases for the product.
This was probably one of the features they petitioned their customers about or vice/versa. If Dewalt thought that a “worksite” dolly was going to save the whole product line, they would have definitely developed and marketed it. As it stands, they don’t seem willing to salvage the product line. Whether that’s because their marketing research indicates it can’t be salvaged in a profitable fashion, or if they’re just wholesale giving up on it, who knows.
Stuart
Like a pit box? I don’t think so.
Plain+Grainy
I didn’t read the long article. But was wondering if you have a favorite storage system?
Stuart
Older-style Sortimo T-Boxxes and Packout drawer tool boxes.
Phranq
I spent a year on a hospital remodel where this system would have been ideal. Commercial contractors usually use knaack boxes, and those provide more security than this, but with less mobility.
I just raided four Home Depots, and rounded up all the clearance DXL that I could find. Got two of the double drawers and one of the single drawers, plus top and two dollys. Just a little over half of the original pricing.
The second dolly is for my first gen Tough system boxes, but the dolly flexes too much with them on there, so that was a bust.
My goal with this cart is to keep it in my shop (5000 sf with smooth cement floors) and keep the tools that I use most often in it, instead of scattered everywhere like I usually do. So it’s a mix of carpenter tools and mechanic tools suited to Tire rotations and oil changes. It’s only been a week, but so far it’s helped me be more disciplined in putting things back when I’m done with whatever the task of the hour was. Don’t think I’ll be looking for another set though.
s
out of curiosity, what does the dxl system do differently for your needs than any one of the numerous ‘service carts’, or ‘mechanics carts’ on the market?
for an example of what i’m talking about, the 6 drawer hf service cart(literally every brand of tool boxes carries a similar model):
https://www.harborfreight.com/tool-storage-organization/tool-storage/tool-carts/34-in-x-23-in-6-drawer-full-bank-service-cart-slate-gray-59854.html
don’t get me wrong. when the dxl system first debuted, i was extremely excited for a modular rolling drawer system that i could essentially self-build my own service cart out of. in my opinion, i think many service carts always manage to get a couple of drawer dimensions wrong, with no way to change it, and i’m left frustrated, stacking tools where i don’t want them just because of that.
but same as stuart found–i played with the system in stores, and just found the overall units clunky and heavy. had they been made of metal, it’s possible the overall size could’ve been reduced by a lot while keeping the same internal volume, but at the cost of even more weight.
Phranq
I have plenty of the traditional tool boxes, and was considering the Milwaukee Cart. But wind blown dust is a major problem for my location. I keep the 16×16 door open most of the time. The DXL drawers are dust sealed, and look like they can handle the occasional cleaning with a garden hose. And this DXL cart rolls better than any cart with casters I’ve come across. I like that all four wheels rotate. It even rolls over air hoses with minimal effort.
At the original price point, I was definitely not gonna go for it, but as I was cruising Home Depots, and noticing the prices drop regularly, I figured give it a try. Still will get that Milwaukee Cart though when/if it goes on sale.
Stuart
I think the Dewalt ToughSystem could be excellent for that.
S
Thanks!
Matt_T
Is “compromised” an appropriate word for the headline? It certainly has compromises. Which is to be expected for a commercial solution. But is it really compromised AKA flawed?
Stuart
It’s not flawed. You lose a lot of space due to plastic strength components (and there’s some steel reinforcement). But it’s made of plastic. It’s to be expected that you need some bulk and weight.
Ram something into it, and it won’t dent like a metal roller cabinet.
There are compromises, and I feel they’re reasonable.
I still like the idea of it. Would I buy it for my own use? No. Could I recommend it to others? No. Would I do anything different if I were on the product design or engineering team? No.
I love the idea, hate the sum of the parts, and hope to see expansion products, even though I wouldn’t buy anything I can envision Dewalt adding to the system.
I didn’t know how to resolve such sentiments. “Reasonably compromised” seemed fair, accurate, and appropriate.
EBT
I like it. I don’t like the price. I have one, with the large wheeled base (the Red/Yellow wheel locks are a misnomer) and a DXL drawer with ToughSystem2.0 drawers and Boxes on that, and top shelf.
Its like this: If the drawers (Single and double) were $99 each, the base $99 and three types of work surfaces (ABS, wood and steel-that one is missing) at $50 each, they would sell. They are durable and mobile. I can add ToughSys 2.0 boxes BUT they don’t fit 100%. I’d rather replace them with two more DXLs. (I have a DXL base, DXL single drawer, then a set of ToughSystem2.0 Drawers, with a ToughSys2.0Box backed up, and then DXL work top. ) But the pricing is still too high for individual components. $329 for a drawer unit? You can have a complete US General steel drawer mobile cabinet for $399.
My only like of it was that DeWalt finally had a storage device that fit its Pneumatic Flooring nailer/stapler. Which I own. And it fits. No other manufacturer storage drawer or mobile solution fit it. Downside is that I can’t take just the drawer as its heavy and unwieldy.
Stuart
The pricing is high, but I feel fully justified for what you get, in the context of its size, engineering, and the cost for modular tool storage products less than half the size.
Alex
Multiple Home Depot location in my area have them “on clearance” and show in stock online. When traveled to 3 different stores, not a single store had them in stock. Weeks later they still show multiple available on clearance at the same stores. Store employees have no idea where they are, they’ve searched pallets on tops of shelves to no avail. Too bad, I have been wanting to utilize them in my work vehicle, and have been waiting for them to be on sale for quite a while.
TomD
Home Depot is horrible at this. They have seem to have no way of tracking the stuff that’s up high and a pallet can be hidden for months. The only thing you can do is either find a friendly employee who is willing to call you if they find it or keep checking.
Stuart
I was excited to see this at Home Depot, and I can see how Home Depot could have been easily convinced to carry the system. Was it a good idea? No.
Walt Bordett
As others have commented, I think this system is best suited to a contractor or facility maintenance worker’s worksite supply and materials organization cart. I can see this used by electricians, AV, IT, Medical Maintenance, and so on. On big jobs they would have a tool cart and supplies carts with what they need at the jobsite.
I don’t see this as primarily tool storage.
William Adams
>For example, if you see it in stores or the product page and think “that’d be perfect for my needs,” it just me.
“it just might be”?
>Some people consider the cart to suitable for ToughSystem tool boxes.
“to be suitable”?
>However, overall, it’s like putting together a sandwich that just don’t satisfy you.
doesn’t?
FWIW, the only item which seems to be on clearance for me based on nearby store stock is the worktop: TOUGHSYSTEM 2.0 DXL 30 in. Worktop — at a suitably deep discount, I’d consider it as either a tool cart for my CNC machines, or maybe for my 3D printer.
Kind of a shame that there isn’t a cart option which would allow getting it up/down stairs — if there was, and it was on sale at a suitable price, I’d find it hard to resist.
Stuart
Thanks! Sorry – *fixed*
This can go up and down stairs, you just to take it apart and find a friend and hope the stairway is wide enough.
“I’d consider it for…” – it doesn’t work well for that. I tried so many different loadouts, and ultimately determined it was ill-fitting for all of them. I tried so hard to make it work, as I really love the concept and engineering.
Frank D.
I don’t see how it is flawed at all. Wheel are always a bit of an issue. I have to unstack my packouts or ridgids too to lift them. They will always be heavy.
Anyhow. I love that fourth photo. This could easily hold all of the most important powertools and some of their supplies for whatever you need to do in an organized fashion. I think it is brilliant. And you get a larger more stable work surface.
I would love to adopt a few on clearance … but they’re not to be found … and they’re still spendy. That and I went pretty deep with Packout as a DIYer. My main tools are in a pile of single units with custom foam. Great and secure; but it lacks the quick access that drawers have. And a single stack is rather small to work on.
Jared
Dolly underneath and a platform on top when combined with regular Toughsystem drawer units is a neat idea. I hadn’t considered that.
I probably COULD use a system like that, but it’s priced out of league for my non-professional use.
Stuart
I tried it like that, but found I greatly preferred single Packout drawer towers, which aren’t very space-efficient but were more versatile.
Richard D
I bought 3 single boxes and one double drawer box and they replaced the tool box in my truck bed. It fits perfectly and I don’t have to dig through a chest to find my tools.
I’m disappointed that we might not see any future expansion but it is kinda neat that they work with the existing DeWalt boxes so I guess that’s the diversity?
Sad I paid full price just for them to go on clearance… I thought about buying more since they were so cheap but I didn’t have a use for them.
I think as tool storage in a shop goes you could make several stacks that can roll out to be used as work surfaces if need be, and would be modular unlike giant Matco or SnapOn tool boxes.
These seem to be for permanent or semi-permanent locations. Not loading or unloading from your truck and taking to job sites.
mark w
Well written Stuart. I enjoy your more reflective posts in general. And you are so right about application fit. I know a cnc manufacturing cell where that cart you show would be the perfect solution. There’s a lot of those in manufacturing. Like all the weird stuff on global industrial’s material handling pages. Scissor lift tables designed just to remove lifting from lower height for ergo, in 7 different flavors on wheels for various factory uses. Or signs made out of fire resistant fiberglass that show the NFPA signage for chemicals used in architectural glass heat treatment.
Stuart
Thank you, I appreciate it! This one was really tough. I gave it a lot of chances, and it ultimately wasn’t for me. Although I’m not sure who it is for, I can’t complain about its build quality or how it all comes together. It is clear that Dewalt put a lot of thought into it. Thus it’s not flawed, it’s simply a very specialized type of workstation and storage product.
MFC
I think you might be a little too gracious to these drawers. Like you said, if you had spent the full price on these, you would be VERY disappointed. I bought three drawer units (two dual and one single drawer) for $100 each and I was disappointed. You got them for free and you still disliked them.
Why?
The size of the drawers are terrible.
The shallow drawers are too shallow, and the deep drawers are deep, but not deep enough for the large tools I want to put into them. Milwaukee drawers are better balanced and provide more utility for all of my DeWalt tools. How is that possible?
Not to mention the fact that these are incredibly heavy, and as you mentioned, do not roll around so easily on an uneven surface.
So, yeah, I wanted it to work, but they just don’t, and I wouldn’t recommend them to anyone.
Harrison
This whole DXL saga, especially the Home Depot rollout, is a bit of a head scratcher.
This is unabashedly a professional product with a steep price- Clearly aimed at commercial contractors and facilities maintenance. So why market in a home store, patronized primarily by DIYers?
I speculate that Dewalt wanted to capture that flagship image that Milwaukee has capitalized on so well, where their true best in class, segment-leading products (Plumbing & electrical specialty tools) act as halos to build confidence in their DIY products like drill kits and lawnmowers. Maybe Dewalt thought getting some big impressive looking cabinets in front of consumers would help sell more Tough system. Maybe they thought people would buy these for their garage.
Here’s the thing though- Milwaukee doesn’t sell their Pro Press / Force Logic tools in Home Depot. (Nor does Makita sell their 10 & 16” circular saws, Bosch their jackhammers or whatever.)
Milwaukee won the professional plumbing market not by merchandising $4000 tools in-front of DIYers, but by building good tools that plumbers love, and selling them through supply stores where plumbers actually shop.
Everyone needs to hire a plumber or an electrician at some point, and you’d better believe they’ll be using red. Witnessing a pro use a tool as part of their trade ( and bragging about it ) is amazing grassroots marketing. Really reinforces the brand in consumers eyes.
Dewalt clearly misunderstood this assignment. Maybe they could eventually be successful by marketing DXL aggressively at Grainger or Uline, doubling down and fixing any of the problems. Sell enough of these to facilities maintenance people, and eventually regular consumers WILL start to see them at work, and be impressed.
Somehow I doubt this will happen given the Home Depot fiasco.
Whenever I see a supposedly class-defining tool line get a home store roll-out, (Flex, ToughBuilt etc) I know they’re in for a bumpy ride.
dandLyons
I have a different take on Dewalt DXL. It actually fits my needs. I will elaborate on that in a moment.
FIrst let me say I have been following ToolGuyd since the start. I was working sr engineer and found (& still find) Stuart’s postings and observations to be amazingly refreshing and informative, worlds apart from the typical clickbait. I have recommended ToolGuyd to every tool user I know.
I have been experimenting with several tool storage systems. In a larger context and for a longer time, I have been experimenting with storage systems in general. A friend’s father summed up my employment history as follows:
“Dan, you went into the military & the Cold War ended, you joined NASA and Mars spacecraft crashed, you went in to the private sector & the tech bubble burst. Could you please let me know what you are going into next so I can pull my money out of that sector of the stock market?”
Tech sector employment was very chaotic. I survived several layoffs. I interview for my own job over and over. I found myself suddenly jobless when the entire business unit was simply eliminated. I was a nomad, moving over and over out of necessity. I went to the jobs.
This resulted in abruptly throwing my material possession into storage units time after time. The demands of the job left little to no time for any other activities. I would end up buying duplicate items to replace items buried in storage. With each iteration, I would try to come up with a better method of storing/organizing.
Cardboard boxes do not cut it for any extended storage in rented space. I have gone through most every form of plastic bins/totes. I started with inexpensive flip-lid transparent file storage totes. I simply stacked them up. I bought them from big box stores. And I ended up with different batches w/ different colored lids. I attached invoice pouches to each box. I printed inventories on different colored paper for different categories of stuff. I included a numbering scheme. I kept a master inventory as PDF and could just search that file to find which bin a particular item was in.
Unfortunately, these bins did not protect against dust/moisture/etc. My rental storage experience included a unit covered in dust/dirt, another in wildfire ash/smoke damage, a third was overrun by rats. Cleaning/moving the bins in all of those instances was labor intensive & not fun. Further, it would turn out that one particular batch of flip-lids was defective and the lids failed collapsing/toppling stack after stack spilling content all over. I eventually moved to the ubiquitous 27 gallon totes. I specifically prefer the Home Depot version as there are also 14 gallon totes that use the same lid and stack.
I also tried using plastic shoe boxes on wire shelving (again big box store buys). My thought was that I could wrap the shelving with plastic and roll it anywhere. Unfortunately I overloaded them. The threaded casters would snap off if the hit a slight bump. I replaced all the threaded casters with a friction fit solid tube model. This held up a little better until the budget shelving tubes started to fracture. Wire shelving is fine if you don’t move it around much.
My engineering career abruptly ended due to health issues some years back. I am now disabled. This has, of course, changed my needs in a number of ways. I must manage my energy and am more constrained in what I can physically do.
Getting back to Dewalt tool storage products. I originally went with TStak (Craftsman VersaStack). I also started experimenting with Dewalt ToughCase+ in all the sizes. When Dewalt ToughSystem came out, I bought a few boxes. I also bought adapters that make ToughSystem backwards compatible with TStak.
The typical criteria of evaluation for tool storage are Affordability, Modularity, & Flexibility. TStak wins on affordability. TStak, ToughCase, ToughSystem are all modular. I have a few pieces of a couple other system. But I hadn’t found anything that quite met my flexibility requirements. I found shortcomings for all makes/models.
In my healthy days, I would brute force my way through work and projects. I no longer have that luxury. While I have 27g/14g HDX totes, I find myself favoring the 9g/7g sizes (2 stack nicely atop 27g/14g totes) these days.
In addition to Affordability, Modularity, & Flexibility, I have an added requirement, Transportability. From my past experiences, I need rugged storage products that easily move. I need to be able to hose off and roll away for quick relocation all the while having everything remain organized/accessible.
I was inspired by BuckyLab at the Delft University of Technology in the Netherlands. I have purchased most of my tools with their mobile workshop concept in mind.
https://buckylab.blogspot.com/p/the-mobile-workshop.html
Since my disability, I have been working on creating a STEAM nonprofit. I moved into a Live/Work Loft where the first floor workspace & a small residential area is on the second floor. I had hoped this would be a stable environment. I focused less on Transportability and just tried to set up some work space.
Well, things have taken a turn. I am now effectively housing insecure as the landlord looks to convert this property to strictly residential. My neighbors have all sorts of interesting creative enterprises going. We are all potentially affected.
I realized that I should never have abandoned the transportability criteria. Due to my current workshop uncertainty, I specifically bought Dewalt DXL (on sale at HD). I also have Dewalt ToughSystem 2.0 boxes. I now have a 4 stack of deep drawers w/ dolly top & a 4 stack of single drawers w/ dolly & top, and a number of standard ToughSystem 2.0 boxes on a third DXL dolly w/ top. I bought both deep and shallow trays.
The DXL is compatible with the ToughSystem 2.0 which is backwards compatible with TStak. I can minimize storage footprint by stacking all of these up to doorway height and rolling it along. I can easily move lots of tools/boxes despite my personal challenges. By combining the all the Dewalt toolbox systems I have achieved great flexibility. My DXL drawers are organized mostly with trays. Metric tools on one side, SAE on the other. The exact arrangement of trays is flexible. I can remove tools or an entire tray. I can place the trays in standard ToughSystem 2.0 boxes or a rolling stack. I can roll a whole DXL stack over to work on my truck. Or I can roll up, open the tailgate and detach the DXL boxes setting them 2×2 in my bed. I can work directly out of these or I can go somewhere, like a boat dock, and restack them.
I am in the process of making my truck into an “science expedition vehicle”. When reading the book Jurassic Park, I really admired the engineer character and his Mobile Field Systems business, I intend to use the Dewalt products for modular storage that I can rapidly install in the vehicle. I already have mobile kitchen gear in a couple boxes, some specific science field kits as well. It is a work in progress.
My point is that taking the Dewalt products in total, one can create an incredibly flexible storage approach.
I originally planned on using ToughBuilt products but the roll out of the products I most wanted simply hasn’t happened. So Dewalt it is.
Thanks everyone for your interesting insights
blocky
Really enjoyed reading your personal account and process here. End of this year, I’ll be moving shop locations for the third time in 5 years. Mobility is at the fore of my mind. Thank you for sharing.
emGee
I ended up buying essentially 2 sets of DXLs from my Home Depot that had them marked on clearance. For me it will be mostly to store and sort the “millions” of tools that I have everywhere. It wont leave the garage. (i have a 4 car garage). I also have 2 Rigid pro tool box sets, 1 Milwaukee Packout set, and the DeWalt 2.0. My side hustle is rental properties that I own. I I can buy a lot of tools and write it off. Also my hobbies include working on off road vehicles and trucks (I have 5)….Just wish I could quit my day job to have more time.