The Complete Guide to Truck Tool Box: Dimensions, Lock Systems and Mounting Methods 

A truck tool box isn’t just an additional accessory to your vehicle. It’s an important investment in safety, durability, and style as well. 

While a quality tool box protects your valuable tools from theft, external elements, and accidents, making the wrong choice can cause further damage. With so many options in size and style, choosing a tool box perfect for your truck shouldn’t be rushed. 

This video is sourced from Youtube@Danny Johnson’s Garage

From DIYers to seasonal professionals, everyone relies on tools to stay efficient on the job or on the go. And needless to say, most tools are a lifetime investment, which deserve to be taken proper care of to perform their best.

But how do you know which is the best truck tool box for your needs? If you find yourself conflicted about the style, size, security, and installation when purchasing one, we’ve got you covered. 

Our detailed guide on the truck tool boxbreaks down the fundamentals of the important accessory, which not only helps you keep your favorite tools organized but also ensures your truck is ready for anything.

Table of contents

• Why the dimensions of the truck tool box matter
• Truck tool box security 101: Protecting your tools with the right locking system
• How to measure your truck tool box
• Step-by-step tool box installation guide
• Installation for trucks with pre-drilled holes
• How to install a tool box without drilling
• Truck tool box FAQs

How to maintain your tool box for extended lifespan

Why the dimensions of the truck tool box matter 

The size of the truck tool box, such as its height, weight, and depth, is crucial in ensuring it properly fits in the trailer tongue or truck bed. While large boxes offer more storage space, they add additional weight, thus limiting maneuverability or trailer balance. 

Similarly, the tool box must be just long enough to allow the lid to open without hitting the trailer or any mounted equipment. A trailer tongue box, on the other hand, is typically installed on the V-shaped tongues of a utility or a cargo trailer, which means the usable space is limited. 

So, proper dimensions determine efficient storage, trailer operations and coupling mechanisms. Tool box sizes vary for every truck. Below are some of the most common dimensions for standard vehicles. 

1. Standard Crossover Tool boxes - Width: 69” to 71”, Depth: 20” to 22”, and Height: 13” to 18”.

The largest of all truck tool boxes, ideal for heavy-duty users or contractors who need maximum space. Usually installed in full-size pickup trucks.

2. Compact Crossover Tool boxes - Width: 60"–65", Depth: 16"–19", and Height: 12"–15"

For mid-size truck owners, such as the Toyota Tacoma or the Ford Ranger, the compact crossover tool box is the best choice, owing to its more compact fit with enough room for basic tools and gear.

3. Trailer Tongue Tool boxes - Width (at front): 20"–24", Width (at back): 36"–48", Depth: 16"–24", and Height: 12"–18"

The trailer tongues tool boxes are typically designed to fit the tongue space without affecting the hitch, while offering safety and weatherproof storage. 

4. Low-profile truck tool box - Length 60” to -72”, Height 11” to 13”, and Depth 18” to 21”

This tool box is slim, horizontally compact, and sits low across the truck bed, without blocking the view in the rear view mirror. It is also lightweight, often easier to install, without requiring drilling holes for installation.

5. Side-mount tool box - Length 48” to 96”, Height 12” to 18”, and Depth 12” to 16” 

Also known as side rail or top-side box, the side-mount tool box is installed along the inner side walls of the truck bed, usually above the wheel wells. It can be accessed from the side of the truck without requiring you to climb into the bed.  

Truck tool box security 101: Protecting your tools with the right locking system

As with any important tool or equipment, it’s an absolute necessity to have an adequate locking system on your truck tool box for several reasons. 

Not only does it prevent theft, but it also ensures your tools aren’t mishandled by others when you leave your truck unattended, which is especially problematic for professionals who rely on their tools to get their jobs done. Here are different types of locking mechanisms for a tool box.  

Keyed Locks

You will commonly find this in entry-level tool boxes for an affordable price. While Standard Barrel Locks are simple and can be drilled through fairly easily, the Automotive-Style Locks are usually better in quality and more secure than the former. The key is also designed to match your truck and can’t be replaced easily if lost.

Combination Locks

A more modern and evolved locking mechanism in a tool box, which uses a code instead of a key to keep the lock secure. The limited access ensures greater security, but you’re also prone to the risk of the code being accidentally seen or guessed by others.

Padlocks

These are more traditional and aren’t immune to powerful tools like bolt cutters, which can easily cut through. However, high-grade padlocks are less prone to damage from external elements and protect your tools from theft, as they can’t be broken into as easily as their cheaper version.

Electronic Locks

Other than a power source and a hefty price tag, the electronic locks are by far the most secure locking mechanism for your valuable tool box. It can only be accessed by RFID (Radio-Frequency Identification) or biometric, thus ensuring convenient access.

Latch System with Internal Rods 

When everything else fails or if you’re looking for a budget option, the latch is worth a shot for securing your tool box. Despite its conventional design, it is generally considered more secure than a single-point lock. However, the internal mechanism is susceptible to rust and corrosion when poorly maintained, resulting in a potential jam. 

How to measure your truck tool box

Every truck is different. A tool box that fits perfectly in one might not be as efficient in another. If you aren’t sure of the dimensions best for your vehicle, follow the step-by-step guide below to measure a tool box before investing in one.

1. Measure the distance between your bed rails 

The side panels that run along the left and right sides of the truck bed are called the bed rails, and the distance between them determines the maximum size of your tool box. 

The distance between the bed rails from the outside is the wider top that sits on the bed rails, and the narrow base is supposed to fit between the rails.

2. Determine the height of our bed walls

The distance between the floor to the top of the rail determines the height of your bed walls; this will also be the maximum height of your tool box. 

3. Identify the distance between the base of your wheel wells and the bulkhead.

Another important measuring criterion is finding out how much space exists between the front wall of your truck bed, right behind the cab - the bulkhead - and the bumps on each side, where the tires rest – the wheel wells. 

Because most truck bed sizes are similar for different models, truck tool boxes come in semi-custom sizes that fit trucks of the same class. While mid-size boxes are meant for beds of compact or medium-sized pickup trucks like Colorados, Tacomas, and Frontiers, the full-size boxes are specifically designed for models such as Silverados, Sierras, Tundras, Titans, and Rams.

Step-by-step tool box installation guide

Installation of a truck toolbox is a heavy-duty task that needs to be carried out with precision. The steps detailed below will come in handy for anyone, from professionals who regularly use trucks to travellers, often seen on the road, as RC Industries suggests. 

Identify the right tool box 

For easy installation of a tool box, you must first find one that’s right for your vehicle. Measure your truck’s bed using the steps we shared earlier, because you don’t want to buy a tool box that’s too big or small to fit. Another easy way to identify the right size is to lower the tool box into place and open the lid to see that nothing is blocking the hinges of the box.

Pick the right tools ahead of the installation

Gather all the tools needed for installation before you take on the task. J-hooks/buts, measuring tape, and wrench are some of the much-needed tools for a secure installation. Also, do not forget safety equipment, such as gloves, a mask, and goggles, for yourself. 

Protect your truck from scratches

Given the material - steel, aluminum, and stainless steel - and the size of a tool box, your truck is susceptible to scratches and other damage. Therefore, for safe installation, always lay down foam or rubbing padding beforehand. However, you can skip this step if your truck comes with a durable bed liner.

Installation for trucks with pre-drilled holes 

• Measure the box placement and drill four to six holes in the truck bed using a power drill at the point where the tool box will rest.
  
  
• Place the tool box in the marked position, and once the alignment is confirmed, use J-hooks or nuts and bolts to secure the box into the location.
  
  
• Tighten the bolts until the box can no longer move or shake around. However, ensure the bolts aren’t overtightened, as it can cause rail damage.

How to install a tool box without drilling?

You can skip the drilling in trucks that come with pre-installed holes in their bed. They are plugged with rubber stoppers, which can be removed when needed, allowing a convenient placement of the tool box. 

The steps for installing a tool box sans drilling are the same as those that need drilling, except you don’t need to manually make the holes. 

Setting up a tool box on your truck bed is a relatively simple procedure, with or without drilling holes. However, it’s highly recommended to get professional help if you’re struggling to do it on your own. 

Truck tool box FAQs

What materials are truck tool boxes commonly made from?

Aluminum, steel, and plastic are some of the common materials used to make truck tool boxes. While plastic and aluminum truck tool box are lightweight and resistant to rust, tool boxes made from steel are more secure and durable. Although they tend to rust if not properly coated. 

Are tool boxes waterproof?

Understandably, you are worried about your tool box getting drenched in rain or being overexposed to external elements. Even though most tool boxes are weather-resistant, but very few are 100% waterproof. You can rather protect your tools by looking for boxes with rubber gaskets and tight-fitting lids for best sealing. 

What is a J-hook and how does it work?

A J-hook is a J-shaped bolt used to secure a truck tool box to the bed rails without drilling holes in the truck bed. It is secured with a washer and nut, and then tightened from inside the box. This attachment is mostly used with crossover boxes and is best suited for non-permanent installation. 

Can I paint my truck tool box?

Yes, you can paint your tool box, regardless of the material it’s made from. While paint made from metal surfaces is recommended for steel boxes, provided you apply primer first, plastic and aluminum warrant special preparation for adhesion.

What are the common tool box lid types?

Single lid - The most common design with one large lid that opens from the middle, covering the entire box. 

Double lid - Two lids that open from the center inward and sometimes come with center-latching. Both lids can open at once or independently. 

Sliding Lid - A more evolved design with a sliding top, often found in specialized or custom boxes. 

Hinged lid - Accessed from the side of the truck bed, the hinged lid either opens upward or outward.

How to maintain your tool box for extended lifespan

Following a few basic maintenance tips naturally makes your tool box more durable.

• Clean regularly with mild soap and water every few weeks. Use abrasive pads for steel or aluminum boxes. You can clean the insides with a vacuum or by manually wiping out the dust.
  
  
• Frequently inspect for leaks or damage in the seams, corners, or hinges. Also, inspect the lid gasket and weather stripping - replace them if worn.
  
  
• Lubricate the moving parts for smooth operation.
  
  
• Tighten mounting hardware such as J-hooks, bolts, clamps, etc., while ensuring they aren’t too tight, as it can damage the bed rail.

Even though a good quality truck tool box could come with a hefty price tag, don’t settle for cluttered gear or damaged tools. The best tool box keeps your tools safe and ready to use whenever you need them. 

Therefore, choosing the right truck tool box isn’t just about convenience, but also about protecting your tools, making your truck work efficiently, and saving your precious time. 



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