Re: [obi] velcroless toggles?
Hi Obi --
I would venture to say that the BASE community, and hence manufacturers, have stayed with velcro over the years because of its simplicity. Snaps have been used (there are still some in use) and various other ideas implemented, but when it comes down to it, snaps and other ways of securing the toggle add complications to the system. Any complication, no matter how small, will rear its ugly head at some point and time -- and that is not a good thing when you have little or no margin for error.
Properly maintained velcro works great and is as simple as it gets, but its down side is the fact that it wears out and you have to replace it often for it to perform properly. (as you've already pointed out) Worn velcro seems to be highlighted even more now-a-days because jumpers are doing more jumps in a shorter amount of time. It still wears the same, but a jumper is more likely to become complacent if he needs to replace velcro every couple of months. (human nature)
I've experienced the same problems as you. I've found that after I replace the "pile" side of the velcro twice, I need to replace the "hook" side of the velcro too. Jumpers often neglect the hook side of the velcro, but that side gets worn too and needs to be replaced. (dirt and grass will also reduce its effectiveness)
I live in the United States, so the bulk of my jumps are slider-down...and a good percentage of those are from slider-down cliffs. Although I've never had a premature brake release in over 600 jumps, I cringe at having a toggle sway around in the breeze when I'm opening close to a solid object. Not just for the worry of a premature release, but also because I may fumble for an extra 1/2 second trying to get my hands into the toggles. For this reason, I take no chances. I routinely check both sides of the velcro on my toggles and if it is even close to worn, I have it replaced. Gear maintenance is one of the variables I can control, and like you, I'll take every advantage I can get.
Back to your question: would a velcro-less system similiar to what is used in skydiving today be safe and effective on BASE jumps? Possibly, but I have reservations. As you mentioned, you may have to slightly adjust the way you release brakes (depending on the design and your current technique). I would also be concerned about the toggle coming out of its hoods during the deployment sequence, leaving you in the same situation as before. (properly maintained velcro is very secure)
But a better design may be out there...
Can anyone else think of any complications or issues that may arise?
Bryan