I currently use an 8 1/2" wedge in my bows. They are 64" AMO with limb length approx. 29". Bingham recommends 10 1/4" wedge for this length bow. Make question is what be "PRO" and "CON" for using a longer wedge? I'll some pics of a problem I'm having with some limbs, just wondering if this might be the cause. Tony

A lot depends on where and how your limbs are bending. If they are bending too close to your riser a longer wedge will push the bend out towards the tip and decrease the working length of the limb. What's your taper in those limbs?

These pics show how close the end of the wedge is to the index pin. This is were I have a problem sometimes. This bow limb started slitting, just the top glass, from the index pin hole down the face about an inch. I thought I had it fixed, but when I pulled to full draw popped the glass lose another half inch. I like having as much working limb as possible, I think this my be a little to much. The taper is .002. Thanks Tony    

Are you sure your hole is deep enough and the pin is not bottoming out into the core material?

Yes the index hole is bore all the way through.

Maybe when you drilled thru you might have made a stress area with a not so clean of a break thru. The end of your wedge will work some so maybe making it thicker so it does not flex as much will help. I used to drill all the way thru and cover with an overlay and had problems with them popping up or spitting over the hole. I then glued a short piece of dowell in the top part of the hole to have something to glue to in that area. Worked pretty good. Now I no longer drill thru.

I also had the same issue with the overlay popping up. I was told by a pro to keep the overlay shorter and not extend beyond the riser.  Also keeping the overlay thinner helps it to flex.

Thanks everyone from the input some good ideas to try. Tony