Possible cause of  failure:  This failure may be due to the fact that the space between the straps of the toggle is too small and the little "T" at the end of the rod is too short. The inside edges of the toggle straps are forced to ride on the weld joint instead of the entire surface of the strap riding on the smooth surface of the "T".  I spoke with  John at Acore Welding and he suggested that the "T" needs to be longer so that a wider toggle with a wider space between the straps can be used. This will allow the full surface of the toggle straps to ride on the full surface of the "T" instead of the edges of the straps riding on the weld joint.
 

  

This is what an original toggle setup looks like. If you look closely at the pictures, you can see that the toggle wraps around the "T" at the end of the rod by means of two straps. The straps are suppose to rest against the small "T" at the end of the rod, not the weld joint. You can see that the straps on the toggle on the left are starting to spread outward. With the inside edge of the straps riding on the weld joint, they will continue to spread, then crack and finally fail.

Inspect your toggles for cracks on the straps. If they are cracked they must be replaced or modified. Remember, all modifications are at your own risk. The toggle on the right has the straps seated properly. The straps are not cracked.