Mike,
This is the method I use: Like Pat said, pre-shape, and bevel the tips before putting them on. I usually take a three or four inch stock piece of overlay material, cut it about ¾” wide, and pre-shape/bevel both ends of the stock piece on my bench belt sander (100-150 grit). Then cut the stock piece in half and have two tip overlays. Leaving the stock tip piece long to begin with gives you something to hold on too and helps prevent an unwanted manicure (Don't ask how I know
). Next, I very, very, very, carefully flatten the back side (mating surface) of the limb tips using the bench belt sander.
Practice grinding a flat surface on some branches before attempting this method on your bow, when you consistently get a good mating surface go ahead and try it on the bow. I have used files, sanding blocks, and scrapers with mixed results. The method described above gives me a flat, smooth surface that yields a thin glue line very little time. Also, I use CA glue and have never had a failure with it. If you use epoxy the surface needs to be roughed up a little and the glue line will be thicker. I have never tried using any of the Tite-Bond glues but think they would be fine. TBIII would be my recommendation because it waterproof. CA and TB glues work best on flat surfaces as their gap filling abilities are not as good as those of epoxy.
