Dennis,
Love these projects! I just found this project:
http://ganoksin.com/blog/pennabilli/2011/10/12/a-knife-from-a-nail/
Which of course made me order a bunch of iron nails! I already have some horseshoe nails, so I'm going to try your projects, too.
Tell me- did you have to anneal the nail in between steps??
-Dana Evans