What is the recommended minimum diameter of toggle bolts used to mount plywood?

The recommended minimum diameter for toggle bolts used to mount plywood is 6.3 mm (0.25 in). This size provides a balance between strength and the ability to securely anchor the plywood to a surface. Toggle bolts function by spreading the load across a larger area behind the surface, making them particularly effective for hollow or thin materials like plywood, where a standard screw might not provide enough hold. A diameter of 6.3 mm ensures that the toggle bolt can sufficiently handle weight while minimizing the risk of pulling out or destabilizing the plywood panel.

Using larger toggle bolts, while they may provide even more strength, can lead to excessive damage to the mounting surface and are often unnecessary for standard applications. In contrast, choosing a smaller diameter would not adequately support the installation, risking failure under load. Therefore, 6.3 mm represents an optimal choice for effective mounting.