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That was a great write-up — thanks for sharing the full process, including the ups and downs. A few thoughts on what you described:
- Ash performance: Ash can be a bit unpredictable for bow wood. It’s easy to work and forgiving in tiller, but it’s also notorious for taking set, especially in shorter designs. What you saw (hinges developing near the tips and general set across the limbs) is unfortunately very “ash-like.” Wych elm should give you noticeably better results — it holds up to compression better.
- Length vs. draw weight: At 60" and aiming for 40 lbs, you were definitely pushing it. As you mentioned, adding 4–6" would have made a big difference in longevity. Ash bows usually prefer longer, lower-stress designs.
- Fire hardening / dry heat reflex: These methods can add stiffness and improve initial performance, but they don’t magically solve ash’s tendency to take set under repeated use. They work best when the underlying design is already well within the wood’s comfort zone.
Next steps:
- Try that same profile with wych elm — you’ll probably notice a huge difference.
- Don’t be afraid to go longer next time if you want 40+ lbs; less stress on the wood means less set and fewer sudden hinge problems.
- Your approach of shooting a lot before final finishing is exactly the right lesson — the wood “shows its hand” after a few hundred arrows.
Honestly, despite the setbacks, it sounds like you did a solid job on the tiller and the build. This one may not be your strongest bow, but it gave you a ton of useful feedback for the next.