....Now, I'm not a skilled or knowledgeable enough bowyer to know all the negativie ramifications of "set"...if that limb took a bit of set to match the rest of the tiller, would that be a problem?
Not necessarily. Sometimes, as in the case with my trade bow, I actually plan to allow some set in a limb to let it match the other one. If that happened here, the set would only be putting the tips in the same plane, the limb bends would not match. I would rather get it all bending because it makes a more durable bow (in addition to looking better). I haven't given up by any means. As I look at the picture again, I think I need to thin most of that thicker section. I'm betting I assumed it needed to be thicker there, but the reality is that narrowing a limb has less impact on draw weight than thickness does. I've left too much thickness. The challenge is that removing thickness can very quickly change the draw weight, or in this case, cause a hinge, so I'll have to go slow and exercise each wood removal a lot. And, to get back to your question, a little set is not a big deal. Bows with a little set often shoot great. It would mean that my tillering wasn't perfect, or my design was too aggressive for the wood. Usually the former more than the latter.
You said 45-50lbs at 28" right? We should make that easily. With a little heat treating we could probably make 60lbs.
I like that we have both the wire work and bow work in progress at the same time, and captured with pictures. I think you'll beat me done though.
George