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Jason,
As long as you are heat treating in a relatively oxygen-free environment, you can nearly finish the blade prior to HT. You can accomplish this by wrapping your blade in stainless foil.
There is always an increased risk of warpage with thinner sections, but I haven't had any problems going to roughly 0.020-0.025 prior to HT.
You are correct to choose 60-61 RC. The reason is that the hardness (RC) to toughness relationship can be exhibited in a bell curve fashion, as opposed to the typical linear fashion of most steels in the hardness range we use. D-2 is actually tougher in the 60-61 RC range than it is a few points higher or lower.
D-2 isn't the toughest steel, but if HTed properly, it will do well for the size of blade you are wanting to make.
__________________
Brett
Bennett Knives
"Frank and explicit; that is the right line to take when you wish to conceal your own mind and to confuse the minds of others." (Benjamin Disraeli, Sybil)
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