Toggle Lock System

Hey Guys, I have been keeping busy with the Skool thing and thought it would be fun to share one of the projects from there.

I do love using these old cigar boxes because they function well, are finished and they all have an unfinished interior to which to glue part to.  I also enjoy that altering a box this way keeps it out of the landfill as so many have over the many, many decades.

The Penny Drop Game was something that I found on You Tube, has no copyright and looked like a fun way to work in showing how to create added value in a product. 

I don't really get into how to make the little slots because I am sure we all have the skills to do this on the router.  I was in a bit of a rush and did not get the perfect results I was aiming for, but satisfactory for the job at hand, which isn't the game, lol.  I will leave you to explore that operation for yourselves.

Basically, I made a 3/8" thick plate to go on the inside with the spaced holes, make this first.  Then I laid it out on the front, just below the line where it would receive the Lock Tab that is attached to the Lid.

I then clamp the Plate to the outside of the front face of the cigar box and then use that as the drilling guide, so when you move the Plate inside, the dowels will run through them with better success with all holes being properly aligned.

I made some simple Toggle Knobs by using online craft store parts and cutting a kerf dado through the one side.  I then glue in a piece of wood into the kerf and it becomes a strong Toggle knob.

I use a model saw, so my kerf is 1/16".

Here they are in dry fit.  You can also see the Lid Tab set in place and where you need to decide which dial will be left vs right positioned.

You will notice that my Lid Tab is not quite at the line above it, which is the final placement.  The 1/16th difference will create a little bit of play in the Toggle unlocking points.  The big reason I do this is because once the Lid Tab is glued on, it is very difficult to sand it now when in place.

I whipped up 4 knobs for the exterior and added 1/4" dowel shafts that protrude the Plate just enough for esthetics.

This mechanism is so easy to build because you can clearly see how well the Toggle Points land.  Adjust any notches in the Lid Tab before you glue it on permanent.

Before you glue the dial to the inside knob, I use thin shims of plastic that I can use in behind the dowel.  When I squeeze the parts tightly together, the shim will leave the perfect gap when removed.

Glue on the Lid Tab.

The only last thing to do is to mark and set the boundary points for the rotation of each Toggle Point.  Ideally, if I was making this again I would have all this sorted out BEFORE I glue the damn Plate in, lol.  Instead I was having to use a tiny hand drill to get in there.  It wasn't terrible, but would be easier the other way.

Here we go, ready to close the lid the first time!  

Anyway, if any of you are brave enough to try this one, remember, Mother and Father's Day are coming....  : )