@gus Thanks for working through all that and giving us the details. Next week the Rust team is meeting in person and we’ll try to regroup to understand the problems you are dealing with, how Cargo can ease them.
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It is possible to use other repos than crates.io, though not super tested in the wild. See this unit test, which frobs registry.index in .cargo/config. @alexcrichton says you might also want to look at the implementation of cargo-vendor.
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I don’t think there are specific plans for releasing binaries, though it’s known to be a desirable feature.