This has been fun for sure.  I went back out and checked the set and the normal limb had gone back to straight.  The character limb still had an inch and a half of set.  I decided to toast the belly of this bow and see if I could reduce the set.  I do like the look of toasted osage.

I only pulled the bow to 26" after toasting it.  The draw weight increased from 51#@28" to 55#@26".  I had a funny feeling and pulled the bow off the tillering setup and found this:

and it clicked that I'd heard a tic at one point yesterday but couldn't find a lifted splinter or crack so I assumed I misheard and went on.  I'm flabbergasted that the bow didn't blow up with such a bad grain violation.  I was only at about 25" of draw when it happened and I went all the way to 28" ... and it held together. 
 
  Osage is good stuff. 

  Not sure how I missed that grain, I remember this stave was a tear-out when trying to get 2 smaller staves from one larger one.   Obviously I was in too big a hurry.  Given that this bow survived up to now I'm going to superglue this one and wrap it with thread.  I had toyed with flipping the tips to improve the string angle, not sure if that's still a good idea or not.  One way or another I need to take more twist out of each limb tip.
George