Toggle Stop Blocks

Dan Neubecker & Dave Tutelman -- March 19, 2005

Cutting

There are two different ways of going about cutting the toggle stops:
  1. A straightforward way.
  2. A safer way, especially if you are using a radial arm saw rather than a table saw. This method keeps your fingers farther from the blade, which can help for a piece this small.

Straightforward way

Cut two pieces ¾” hardwood pieces, 2”long x 1-1/2” wide, with the grain running lengthwise.  One of these blocks will be become the shaft marking toggle clamp stop and the other will become the shaft profiling toggle clamp stop.

Cut the notched area out of the shaft-matching stop.

Safer way

Start with a piece of hardwood 3/4" x 1-1/2", and more than 4-1/4" long. This allows two 2"-long blocks to be cut from it. But do not cut the blocks yet.
First cut the notched area, as if the piece were only 2" long. You have a lot of wood to hold while you are doing this, much safer than trying to hold a 2" piece while you notch it.
Cut the notched 2" piece from the larger piece.
Holding whichever end is longer, cut another 2" piece, which will remain rectangular.

Drilling and finishing

Now you need a receptacle for the plastic inserts.  Start by boring a ½” dia. x 1/16” deep counterbore in each piece, followed by the 3/8” hole to the depth shown in the plans.
 
Round or chamfer the edges around the outside of the toggle stops adequately to clear the toggle clamp when the stops are rotated into position.  Sand and finish them as desired.

Assembly

Install the toggle stop adjusting hardware.  The 3/8” plastic insert has a 1/16”x1/2” lip that should fit into the counterbore so that the insert is flush with the surface.  You should be able to tap it into place with a hammer.  I suggest gluing the insert in with wood glue as well.

Install the 1-1/2” hinges to the toggle stop blocks as indicated in the plans.
Install the toggle stop blocks on the toggle board as indicated in the plan, by screwing the hinges to the toggle board.  Note: it is important that the toggle stops be installed flush against the bottom of the vertical support blocks for the toggle clamp.  In this way, the toggle clamp support blocks provide support for the toggle stops when they are rotated out into position for use.