I use a 4 1/2" grinder with a cut-off wheel (about 1/16" thick.) Trace your pattern and rough cut with the wheel. Then you can switch to a grinder wheel (about 1/4" thick) to do your rough shaping. After that you're on to hand filing, and belt sanding. Hope this helps.
Ebay for the Antler pieces, fancy brass guards can be purchased from a number if different knife supply stores (texas knife, jantz supply, etc.) I make most of my brass guards from bar stock.
Once hardened, it will still be pretty hot. I would let it cool enough to clean it off, and then put it in the oven, lying flat, at 400 F for about 2 - 3 hours. This will temper it, making it a little less brittle. Hope this helps!
I use a 4 1/2" grinder with a cut-off wheel (about 1/16" thick.) Trace your pattern and rough cut with the wheel. Then you can switch to a grinder wheel (about 1/4" thick) to do your rough shaping. After that you're on to hand filing, and belt sanding. Hope this helps.
Good Luck,
John