Could we not tiller to draw weight and bend design no matter what the woods properties are? Also Allen did test on the wood.
Yes, the actual wood properties don't matter much as long as they are consistent throughout the stave. Doing bend tests on the drops should get you close enough to be 98% or better of the design results unless the wood is really inconsistent. Heating it to bend may alter your properties, but osage seems to be super tough and resilient to every sort of abuse, so hopefully it doesn't change too much. With the stiff handle design the heat there shouldn't matter, it's more the recurves that may have a noticeable change.
The red line is my design thickness at this time. I got to narrow the width some . Then it will still be heavy but may be able to brace it. Will bracing to heavy cause set?
If the weight comes from excess width it won't cause set, if it comes from excess thickness it could. When I did my maple bow I used a set of vernier calipers to get the thickness as close as possible to the design amount, measuring down to at least 0.005". Width is more forgiving, because it doesn't cause extra strain in the wood.
Since it's Allan's design I would ask him what he thinks of this, but I would say you want to get the thickness as close as possible to the design value and then do any tillering adjustments on the width if you can. Thickness determines how much strain the wood sees for any given amount of bend, width just adds or subtracts weight without changing the actual strain the wood sees.
Mark