DeWalt ToughSystem 2.0 Drawer Mods

The DeWalt ToughSystem drawers are an awesome portable toolbox for quick tool access, but here are a few ways that they could be made even better.

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STACKING (How to remove the wobble)

When stacked, the drawer tool boxes are not stable and wobble a lot. The taller the stack gets, the worse the wobble. There are cutouts in the lid for the feet to fit into, but the cutouts are so deep that the feet never bottom out.

I found some designs available to 3D print, and some to buy. The available 3D print files were too thin for my use. They were 7mm thick, which was an improvement, but still allowed the tool boxes to wobble when stacked. I used some shims to test the ideal thickness, which was 8mm for my boxes. So I redesigned the pieces from scratch, made some improvements, and have published them with a range of thicknesses so that you can print the perfect thickness for your needs.

Test the 8mm thickness first, and then adjust as needed.

The 3D printing files are available to download here:

• DeWalt ToughSystem 2.0 Drawer Anti-Wobble / Anti-Tip Adapter | Multiple Thicknesses for Tightest Fit

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DIVIDERS

Unfortunately, the DeWalt ToughSystem 2.0 drawers do not have any provisions for dividers. They were designed to use foam inserts. I prefer to add dividers to maximize usable space.

I designed some 3D-printed divider ends that can hold a cut-to-length piece of coroplast (plastic cardboard commonly found as free yard signs) or a 3D-printed divider. Coroplast is free as discarded yard signs. The end brackets are quick to print and easy to install.

The 3D printing files are available to download here:

Drawer Dividers DeWalt Toughsystems 2.0 3 Drawer

MATERIALS:

• 3D Printed divider ends (Print in PETG for longevity)

  
  

• 3M Dual Lock Low Profile

  • Where To Buy - Amazon - 3M Dual Lock Reclosable Fasteners, Heavy Duty, Clear, TB4570/SJ4570, 1 in x 10 ft Mated Strip, Industrial Use, Indoor/Outdoor, Great for Metal, Acrylic, PC, ABS, Powder Coated Paints, 1 Roll

  
  

  

• Coroplast - 4mm thickness

  • Free from yard signs

  • Where To Buy - Amazon - 24" X 36" Coroplast Sign - 4mm - Blank White Plastic Sheet Board - 2 Pack

To attach the brackets to the drawer side walls I used low profile 3M Dual Lock to make them easy to remove or reposition if needed.

The brackets have holes for screws or pins to retain the dividers if necessary. So far I haven't needed to use this feature, but it's there if you need it.

Another drawer example. Here you can see the writing on the yard sign Coroplast material that is used for the divider.

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TOP HANDLE

The DeWalt ToughSystem 2.0 drawer tool boxes are missing a top handle. Theres a space for the top handle, but it is not there. Instead, there's an insert in that space. Maybe they removed it because they were worried the handle would break from an overloaded tool box.

The handle part number is: H1400196008. This is the same handle used on some t-stack boxes. This handle was available separately as a replacement part, but it is getting harder to find.

WHERE TO BUY:

https://jackssmallengines.com/jacks-parts-lookup/part/dewalt/h1400196008

This is the Tstack box from which 2 handles can be taken to use on the Toughstack 2.0 drawer boxes.

WHERE TO BUY:

DEWALT TSTAK II Tool Box

3D Printed Handle

A 3D printed handle design is available. The handle grip appears to be very square and not very comfortable.

WHERE TO DOWNLOAD:

DeWalt Toughsystem 2.0 drawer tool box handle.

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MOBILE BASE

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Affiliate Disclaimer

The products shown here were purchased by me with the intent to use them. I did not receive any free items, and I am not being paid or compensated for this review. The video, description, and comments may contain affiliate links. If you click on a link, I may receive a commission. Money earned helps to support my channel and bring you more informative videos about engineering, crafting, and DIY