I've read on here (I think) of at least a couple of instances where a tip overlay popped off. I know there is a hog hunting video that Clay Hayes posted where he popped a tip overlay off getting out of his vehicle before daybreak. I can't remember what caused it, but I'm thinking he dinged it on something. Regardless, he actually was able to find the overlay on the ground outside his truck once he realized it was gone, and he was able to reapair it and continue on with his hunt. Fortunate.
I'm hard on my equipment whether I'm trying to be or not, and I can absolutely see getting my bow tip slammed in a door or stuck in the crook of a tree on the walk in or having it not clear my stand during a shot etc...any number of things that could cause it to pop off. If it can happen to anyone, I can assure you it will happen to me.
I'm wanting to experiment on some scrap limb tips and try to come up with some type of hidden pin system or maybe just actually drill a couple of very small diameter holes completely through the overlay and the bow tip and pin them with matching diameter contrasting wood pins...or even aluminum or brass or copper pins...something soft that can be filed and sanded smooth and would actually look like an asthetic addition or compliment to the bow.
I'm pretty sure that all the failures I've read about were due to a shearing type of force.
I'm certain that something was not done exactly right with the glue line and/or glue-up on these failures, but I'm equally certain that none of the boyers that experienced the failures thought that they were doing or realized that they did anything wrong.
I figure that the additional stability and structural resistance to shearing forces that might occur in the plane parallel to the glue line and the additional and directionally-different surface area of the pins for glue adhesion would make any well mated and properly glued overlay/bow interface absolutely bombproof...and for novice wood workers like me, it would add a little insurance to a job where an unknown mistake was made during the glue up.
I'm definitely going to try it on the next bow I've got roughed out and will start working on when I get beyond my upcoming Elk hunt. If anyone wants to play with this idea and put it into action prior to that, I won't be jealous that you beat me to it.
I'm difinitely going to try it though, as I would absolutely come unglued (pun intended) if I got to my hunting destination only to figure out that my bow was useless because of a tip overlay malfunction.