[Crex]

Originally Posted by WBE

For that notch, I draw it out on the blade, spray over the drawing with lacquer or hair spray to protect the drawing, drill a hole for the tight turn in the scroll, then attack with jewelers files. Once you have drawn it out, and are happy with your design, it becomes more a matter of sweat and labor. The required skill is more in the design layout, rather than the execution. With care, some of it can be done using a Dremel tool.

I do it pretty much same way (pre-HT). I use a flexshaft (dremel like object) to shape, clean up and polish. I also use a fret or jeweler's saw for cutting out the more intricate designs.
A hint for the dremel users: You can "razor" edge one of the cutoff discs with the small abrasive stone that comes with most dremel packages. Use it to shape the edge. Then you can cut those fine notches and V cuts faster and tighter than with a needle file. Does take steady hand and practice.