Edge was ground too thin...
I strongly disagree. I've made plenty choppers/camp/combat/survival knives out of various alloys with edges that thin (.015" or less) at 58Rc, tested 'em pretty dang hard, and
none of them just smooshed over like that. None of them chipped out or broke, either. FWIW, all of my blades to date have been HT'ed by Peters'.
In my experience, good steel with very keen geometry and pro-level HT will withstand a
helluva lotta abuse. Much more than you might expect. There's something very wrong here...
Josh's pics and descriptions do not show "minor rolling", they exhibit
major deformation. That just ain't right. I doubt very much that it was caused just by grinding too aggressively after HT, and I strongly suspect that grinding it back further ain't gonna "fix" it.
Josh has said he had the knife independently tested, and it came out to only 53Rc. That's WAY too soft for a camp knife, and goes a long way towards explaining why his knife just bent in that manner.
My guess is, unless the steel just isn't what his vendor said it was (it could happen), something's deeply wrong with the HT. That could happen, too. If it were my blade, I'd be making Brad's phone ring every hour on the hour until we figured out WTF is going on.
I have no dog in this "fight" but I do have full confidence that Brad will bend over backward to help Josh figure this out and make it right. :thumbup: