If all else fails, you gotta get a REAL smith who can actually work with metal, that is, grind down the offending part and tig or mig weld a larger piece without ruining the temper. He'll also need to re-shape and chamfer or otherwise round off all sharp corners, checker or groove it and refinish it. Sounds like a lot of work. Iffn he be a good one, you ain't getting it back anytime soon.
