Plywood's too rigid and brittle - you may be increasing the strength of the toe a little but you're making it more likely to crack off somewhere, as has happened in the end. Looks to me the willow has moved a bit, as it often does in that spot, and because the ply can't deform with it you've ended up with a blown out toe behind where the ply has cracked. Have seen lamitoes end this way before, I'd guess it's a common result.
You'd possibly want something that will add some strength but ideally compress a little when hit hard, particularly in this case where there's so little willow behind the repair. More realistically I think I'd just use a piece of willow as it's a nice safe option, with a careful choice of non-brittle adhesive. For this particular repair maybe just remove everything rear of the insert (and a bit above that) and put a decent size new block of willow in to replace it.
Just spotted your post about a titanium insert - would end with a totally destroyed toe I'd say! Sandwiching your 1cm of willow between a hard pitch or cricket ball and a piece of ti is only going to have one loser.
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Topic: Suggestions on TK Lam repair (Read 8330 times)