I gave up on using the cutoff wheel and instead finished reshaping the tang with what remained of the grinder's flap disk. So far, so good.
I finished planning the hilt with a tracing of the new tang shape. As you can see here, the new shape leaves the original pin holes badly off-center, so a new set was required. Luckily, I've just finished setting up a mini drill press in the basement which ought to work for this purpose...
... but didn't, or at least not well enough. To be frank, after how fast the flap disk reduced the edges, I expected the drill to punch through with ease like I've often done with a drill press on mild steel. The 3/16-inch bit made the nagel hole with difficulty, but the 1/8-inch bit refused to go more than partway through. After that, it spun and heated the tang but refused to go any deeper. Even annealing the tang didn't help. Now the drill bit's tip is blue and looks blunted. I may not be able to finish this step until I pick up a replacement.
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