I look forward to your results. How are you molding your sugru? Some fellow mad scientist/dartsmiths are also experimenting with sugru in HDPE cutting boards with holes bored in them with countersink bits as dart molds, too. How are you molding yours?
Here is something shmmee came up with: Image Yes, they end in a point, but there are other discussions on how to alleviate that.
Again, that picture is NOT MINE. It belongs to shmmee, but I think it's worth sharing.
They are simply not heavy/aerodynamic enough to work well with powerful guns. The nuthead was just barely thicker than the foam, making easy loading into barrels difficult.
Has using a single BB (or anything else heavy) under the countersink bit been considered? I feel as if this may solve the "too light" problem, while maintaining the aerodynamics of the molded dome.