A Guide to DeWalt ToughSystem and TSTAK: What’s the Difference?

Round about the time DeWalt decided to completely upend the cordless tool sector and release its now legendary XR line of tools, running on upgraded 20 or 18/54V batteries, the company also saw the need for versatile and durable tool storage solutions all of us needed. This is when the TSTAK storage product line was conceived. It consisted of several tool boxes in different capacities, made of hardwearing polypropylene, and with innovative features that meant boxes could be stacked one on top of the other and used with a neat go-anywhere trolley. Each box had metal hinges and latches, provisions for locking, easy-to-use stacking latches to get the boxes on or off, and a decent loading capacity of 30 kilos.

Fast forward a few years and the system has been replaced with the TSTAK 2.0, and seen quite a few improvements. The first version needed to be priced right, as this is when the tougher, better built and more capable ToughSystem also met its first customers. Buyers had quite a few choices, and the company’s storage options have now been upscaled with the recently updated Dewalt Tough System 2. So, how do the different versions compare? If you’re just getting your first portable tool storage package (no matter the brand of your tools), you’ll want to know how one system is better than the other, and what you get for your extra cash.

What’s Good About the First TSTAK?

source: dewalt.com.au

The original TSTAk paved the way for all the goodies DeWalt today offers when storing, organising, and protecting your tools and tool accessories. This is a flexible platform that comes in different box combinations, so will be handy in both small and large projects involving one or several tools. There are several boxes to choose from, each getting bigger in size.

This ranges from the TSTAK I with an included top organiser and 14 litres of space, the deep tool box with 23 litres, a tote tray and room for larger hand and power tools, boxes with integrated extension drawers for small odd bits and fasteners, larger roller boxes where mobility is important, and different accessories like the TSTAK dolly, a collapsible trolley, and foam inserts and moulded inlays (compatible with different tools).

Some boxes are packaged with tools and batteries and if there’s a need for mobility and space in one complete and affordable package, go with the TSTAK tower and integrated boxes. Since the system has been around for over a decade, there are good deals to be had if you shop around. The only thing missing is the higher loads and possibly the IP54 rating of the newer version.

Updating to the TSTAK 2.0

The updated system addresses the few shortcomings of the first version. This also has the same 30-kilo capacity, so will easily hold two cordless tools, a few batteries, and a couple of extras. Boxes are built of the same 2.5mm thick polypropylene, being both light and durable, and there are the same locking capabilities. What’s new are the metal pin modular latches that make stacking and removing boxes easier and quicker, the reinforced metal hinges made to a higher standard, the IP54 rating with included seals for protection against dust and water, and the fact that the system can be used with DeWalt’s Tracker option to locate where the boxes are at any given time. Box sizes and layouts have remained relatively the same. The few added features to the new system though mean that on the whole this is a bit more expensive.

How About the ToughSystem?

source: dewalt.com .au

Like the first TSTAK, the original ToughSystem was released way back in 2011, and geared more towards heavy-duty use, with bigger and deeper boxes, able to carry more tools and accessories in a single go. This meant that the carrying capacity increased to 50 kilos, and that was more thought and effort put into the build. Boxes were 4mm thick reinforced affairs, able to survive a 1-metre drop with a 25-kilo load, and the upgraded IP65 rating meant that units could survive heavy downpours without issue. Like the TSTAK, this was a stackable and lockable system, meaning boxes could be used one atop the other for quick transportation.

DeWalt made significant improvements with the revised ToughSystem 2.0, including a few nice touches that upped usability and security. There are larger two-piece metal front latches, a thinner 3.5mm reinforced casing that helps with the improved and increased storage capacity (by 20 per cent), the ability to stack half modules, largely thanks to the improved one-touch auto-locking side latches, the inclusion of pressure release valves and eyelets for padlocks, panel inserts for easy tool and parts identification, tougher and wider handles for more comfort and more variety when it comes to different storage solutions.

Popular boxes are the DS166 with 2 removable organiser cups as well as internal dividers for larger tools (building on the original DS150 with 1,5 litres of added space), the DS300 which grows to 30 litres, and the DS400 which also includes a top organizer bin unit with removable dividers. If you need more capacity and the advantage of portability, go with the 4-in-1 system that has all three boxes mentioned as well as the DeWalt Tough System 2 mobile carrier to save you save cash instead of buying each separately.

Packing and organising parts and fasteners are handled with the shallow and deep tray bins, which can be combined with foam inserts, as well as a 2-drawer lockable unit with a 10-kilo capacity, or a deeper 3-drawer unit that can combine fasteners and larger tools in one neat package. This ups capacity to 20 kilos.

The system also offers racking units in different configurations, for storing and organising boxes, bins, and drawers in garages or workshops. This will save you considerable space and makes tools more accessible.

Which System Do I Go With?

If you want all the bells and whistles, go with the tougher build and larger capacity of the newer ToughSystem 2.0. This moves stacking ability and mobility up a level when compared to the older ToughSystem as well as both versions of the TSTAK units. It has a better build, can stand more abuse, has better-configured storage options, has more versatility, and will last longer in day-to-day use.

For working pros, this is the storage system to get. That’s not to say that the other systems fall short. If you have fewer tools or use them occasionally in the odd DIY project around the house, then the first ToughSystem or any TSTAK system will do a good job in storing tools, parts, fasteners, and other gear you have. And this is for a lower asking price. What you ultimately choose will depend on your needs and how much you’re willing to spend.