It took a long time for me to decide what to do about the fork. I eventually came up with a solution, sort of, because the project is now going in a somewhat different direction. We're starting with a period
two-tined fork from Crazy Crow (the buffalo horn scale version only because it's the cheapest).
The first step is to remove the scales. I first wrapped the tines in a scrap of soft leather, clamped them firmly in a vise, and ground off the ends of the pins with the angle grinder flap disc in case they were peened. They may not have been, although making the pins shorter can't hurt with the next step. Grinding animal horn does produce a foul odor, so it would've been worth either doing outdoors or by less aggressive means (or avoiding altogether) if possible. Luckily, I have a basement to work in.
I next gradually jimmied the scales off the tang. This is made much easier by the fact that they aren't secured with any kind of glue. In fact, the stuff between the scales and tang is a greasy, grimy substance similar to oil-based clay. That might even be what it is. I don't know why it's there, but maybe it helps prevent rust.
There was already a tiny but noticeable gap between the tang and one scale. I inserted an X-Acto blade tip-first, first at one end, then the middle, then closer to the bolster, and continued until the gap had opened up all along one scale. I switched to the other scale, which was loosening up, then expanded the gap with a thicker knife blade until the scales could be yanked off.
I drew the new shape of the tang on with a paint pen, then it was time for more angle grinding, and finished up by filing the edges smooth and polishing them with grades of sandpaper.
The last step in modifying the metal part itself was to straighten the tines in a vise so that they would more easily slide into the sheath. This was not difficult - the fork appears to be made of mild or un-hardened steel - but it did result in the tines having a slightly wavy profile.
