Thanks, PatM. Thought that was yours. So, are you going to answer the question? How did you get the inside surfaces of the V splice smooth enough for glue up?
Interesting write up on PP. Shows there's more than one way to skin a cat. I wondered about running the backing right up to the tip, but I thought it would be unnecessary.
Anyway... some progress. Roughed in some pin nocks, cut some shallow string grooves on the back of the static tips, and narrowed the tips down further to 1/2". I'm still debating whether I should reduce the tip thickness... I can always do that at the end without effecting tiller. I put it up on the tiller tree to have a look. Bending nicely, but not a bunch, but I safely pulled it to 45# (target weight), and it didn't fly apart. Phew. String alignment is bang on... no twist. Yah!