Thanks for the reply!
I made a few "test-shafts", but combined the idea of the hardwood dowel insert ...with 3" of 2117 aluminum outsert. My plan was to split the additional flexing between the insert and the outsert, AND to avoid the possibility of getting the curve wrong, hence making noisy shafts.
Here is what I'm shooting:
30" (BOP) of CX Maxima 350 shaft (8.2 GPI)
+ 3" of 2117 outsert
+ ~90gr. brass inserts (I had to file off some diameter to get the 2117 to slide over top)
+ 4" of maple doweling (3" glued next to the brass insert, then only 1" of unglued parabolic taper at the back end),
+ 75 gr. steel broadhead adapters,
+ ~145gr. modified Grizzly's (were 160gr.)
+ 5" of fletching wrap
+ 3 x 4" parabolic feathers
Total weight: ~645 grains (including broadhead)
23" balance point from nock (including broadhead) = 26.7 EFOC
They seem rock solid, and they are completely quiet. However, I had to cut them down to 29.5", and they still show slightly weak! (I'm guessing my poor release is robbing me of a LOT of energy, or causing the bareshaft to impact to the right of the fletched shafts.)
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Thinking more about it ... I believe the "ideal" external footing would be an aluminum shaft where the OUTside tube has an extremely exaggerated chamfer - in effect, creating a tapered aluminum outsert. (Is this how the Grizzly Stiks are shaped?)
Better yet would be to couple that with an internal footing - possibly made from hollow aluminum tubing - where the INside of the tubing is tapered down to almost nothing towards the back.
I sure wish somebody would start making steel inserts (threaded) - to replace the brass inserts for additional strength.
I'll try to post a pic of the shafts I made.
-Allan