Try indexing the plunger to be flush with the lock ring and face when the lever is in the down position. The two #4 posts I have are both set up like that.
Height and width of toolholders are almost irrelevant. You could make a thin one or a thick one. Each tool holder has its own height setting bolt, so they will fit no matter where the finished tool height is in relation to the post. The system is tolerant of variance in that sense.
I haven't found any prints, but I can measure and post the dimensions of a #4 holder by the end of the week. They are super simple- a dovetail, a tool slot, and a few threaded holes.