Tool boxes aren’t the flashiest part of your kit, but they’re one of the most important. Whether you’re keeping your tools protected in the van or hauling them across a jobsite, the right storage system can save time, protect your gear, and spare you from rummaging through a box that suddenly feels like a lucky dip.
Dewalt offer two of the most popular modular storage ranges around: ToughSystem and TStak.
Both have loyal fans, both are built to last, and both have their place — but they’re not designed for the same kind of work.
In this ITS Hub Article, we compare the two systems, look at what’s changed in the 2.0 upgrades, and help you choose the setup that actually suits the way you work.
What is Dewalt ToughSystem?
Dewalt ToughSystem is designed for tradesmen who work in tougher environments — the kind of jobs where everything gets covered in dust within five minutes and the weather forecasts are “optimistic guesses”.
Made from high-density polyethylene, ToughSystem is built for impact resistance and harsh use.
Every module is watertight and dustproof, so your tools stay protected even when the jobsite looks like a weather test facility.
Its modular design gives you loads of flexibility:
Stack boxes securely, add drawers, attach wheels, and customise your setup to match your workflow.
With ToughSystem, you get a full range of storage options, from compact organisers and toolboxes to deep drawers and mobile trolley setups, making it easy to build a stack that fits everything from small fixings to bulky power tools.
If you regularly work outdoors or on busy, uneven sites, ToughSystem is built with you in mind.
What is Dewalt TStak?
TStak is Dewalt’s more compact and affordable storage system.
Made from high-impact ABS plastic, it’s durable enough for everyday use but not quite as extreme as ToughSystem — and it doesn’t need to be.
TStak modules aren’t watertight or dustproof, but they’re:
- lighter
- easier to carry
- and better suited to indoor or controlled environments
You still get full modularity, drawers, organisers, wheels, clip-on accessories — the works.
For many trades, it’s more than enough. For some, it’s ideal.
Do I need to only choose one system?
ToughSystem and TSTAK are built as two separate storage platforms, each designed for different types of tools and loads.
That said, Dewalt makes it easy to run both without compromise, thanks to the ToughSystem to TSTAK adaptor plate DWST08017-1.
The adaptor locks securely between the two ranges, allowing TSTAK boxes to stack directly onto ToughSystem units with a stable, rattle free fit.
This means you can keep heavier kit and power tools in ToughSystem boxes, while using TSTAK for smaller tools, organisers, or grab and go cases, all within a single stacked setup.
If you have ever tried mixing the two systems without an adaptor, you will already know the frustration, uneven stacks, sliding cases, and that constant feeling that something is about to topple over.
The adaptor completely removes that issue, creating a clean, secure connection that feels like it was always meant to work that way.
For trades already invested in both ranges, or anyone planning a flexible van or workshop setup, it is a simple addition that makes a noticeable difference to day to day organisation and transport.
Which one is right for you?
If your workday includes rain, cold mornings, dust clouds, or anything involving concrete cutting, ToughSystem is the safer choice.
If you mainly work indoors, carry lighter tools, or just prefer a system that’s easier to transport, TStak fits the bill without the extra cost.
| Feature | ToughSystem | TStak |
|---|---|---|
| Material | High-density polyethylene | High-impact ABS plastic |
| Durability | Very durable | Durable |
| Watertight & Dustproof | Yes | No |
| Price | More expensive | More affordable |
TStak Vs TStak 2.0
A few years ago, Dewalt announced the launch of their new TStak and ToughSystem 2.0 Tool Boxes, but what is the difference between the two and how do they stack up against the originals?
| Feature | Original TStak | TStak 2.0 |
|---|---|---|
| Capacity Load | 30kg | 30kg |
| Stacking Latches | Plastic modular stacking latches | Metal pin modular stacking latches |
| Lockable | Yes | Yes |
| Body Material | 2.5mm Polypropylene body | 2.5mm Polypropylene body |
| Hinges | Metal hinges | Metal hinges |
| Latches | Metal latches | Heavy duty metal latches |
| Water & Dust Protection | None | IP54 water and dust seal |
TStak 2.0 is made from the same high-impact ABS plastic as the original TStak, but it has been reinforced with metal inserts at key stress points. This makes TStak 2.0 more durable and resistant to damage.
The original TStak is not watertight or dustproof, whereas the 2.0 version has an IP54 rating, which means it is protected against water jets from any direction and dust. This makes TStak 2.0 a better choice for use in wet or dusty environments.
Original TStak modules and the newer TStak 2.0 modules are compatible with each other. So, if you decide to upgrade, all newer kit boxes will be backwards compatible with your originals.
ToughSystem Vs ToughSystem 2.0
ToughSystem is like TStak’s older brother. Its tough outer body can withstand drops of up to 3 feet, making it the ideal solution for working on and around job sites.
The metal hinges and latches have been sprayed for 24 hours straight with a water/salt solution with no reported corrosion damage, and their IP65 rating makes them almost fully waterproof. Your tools and accessories will be fully protected from the elements with ToughSystem 2.0.
Original ToughSystem modules and the newer ToughSystem 2.0 modules are compatible with each other. So, if you decide to upgrade, all newer kit boxes will be backwards compatible with your originals.
| Feature | Original ToughSystem | ToughSystem 2.0 |
|---|---|---|
| Load Capacity | 50kg | 50kg |
| Outer Casing | 4mm thick reinforced outer casing | 3.5mm reinforced body |
| Compatibility | – | Backwards compatible with original ToughSystem |
| Storage Capacity | – | 20% larger storage capacity |
| Latches | Metal latches | Durable two-piece metal wire latches |
| Lockable | Yes | Yes |
| Stackable | Yes | Yes |
| Water & Dust Rating | IP65 | IP65 |
| Extra Features | – | Half-width module compatible |
Both the original ToughSystem and ToughSystem 2.0 are made from high-density polyethylene, which is a very durable material.
However, ToughSystem 2.0 has been reinforced with metal inserts at key stress points, which makes it even more durable.
The original ToughSystem has an IP54 rating, which means it is protected against water jets from any direction and dust. However, ToughSystem 2.0 has an IP65 rating, which means it is also protected against low-pressure jets of water from all directions and powerful jets of water from specific directions.
This makes ToughSystem 2.0 a better choice for use in wet or dusty environments. The outer casing is also now slightly thinner on the new model, which gives you a 20% larger storage capacity and it is tracker ready, meaning you can pair it with your Dewalt Tool Box app so you never lose it again.
What is the best toolbox?
It all comes down to your trade, your environment, and how your tools get used.
Choose ToughSystem if:
- You work outdoors
- Your tools face harsher conditions
- You want maximum protection
- You don’t mind paying more for durability
Choose TStak if:
- You work mainly indoors
- You prefer lighter, easier-to-carry modules
- You don’t require full waterproofing
- You want a cost-effective, modular setup
Both systems are lockable, durable, and designed to keep your tools organised.
And both 2.0 ranges are fully backwards compatible with their originals, so you won’t lose previous investments.