Pearl: "Every bow, every piece of wood, and MOST importantly every bowyer is different. What doesn't work today will work fine tomorrow, or for the next bowyer." This is pretty darn true and full of wisdom to start with. As with anything else, you are going to have shimmering victories and crushing, baffling defeats. On every one of my top ten best bows, I swear, I am asking myse;lf how I got away with it, or at least feel like I stumbled over excellence while doing what I usually do
Greg: "I keep asking but is there a point where too thin limbs actually increases the likelihood of a bow breaking?" I don't think so, not in theory, Greg, but VERY thin limbs can create some problems. Baker mentions once in TBB that he thinks kids' bows are harder to tiller. When the limbs are super thin, and especially when flat, the TINIEST differences in thickness or strain distribution CAN be amplified. Like, if a limb is 3/4" thick, ten scrapes at one spot may not even register, but if it is 1/4" thick, suddenly that is a hinge.
Willie: " I would suspect something had changed with the bows that broke. went out of tiller? got too dry?" I would agree with Willie here. Maybe some other factor than what he mentioned, but look for what's different.
Now, I really thought you HAD that maple bow! I thought it was pretty impressive, honestly, but that brings up my next thought. That bow was a REFLEXED, RECURVED, HEAT-TREATED, HEAT STRAIGHTENED (which was a wrestling match) STEAM-BENT bow made of, I wouldn't say INFERIOR, but certainly not PREMIUM wood. I remember how much propeller twist that stave had, etc... and I think, maybe if you had made a 67" flatbow with 2" limbs, flipped tips, and a short handle, it might be a shooting bow right now. I personally wouldn't have tried what you tried with that piece of wood. And, it wouldn't have been so thin if it hadn't been so reflexed/recurved. It just all adds up to strain.
Anyway, that's my two cents. That tiller on the maple should have been money, so I don't actually know.