if your water jet "guy" charges you a $200 minimum,,then you need a new waterjet guy. my local water jet guy charged me $13 per blade to do three blades. So he has no minimum charge that I know of .Waterjet is the way to go if you dont want to mill them out. The last 5 blades i have done i milled the profile out for each blade. It only took about 30-40 mins each blade IIRC.
im not sure if you are able to but cutting out side would provide much better air circulation and less of the bad chemicals around you.
not to hijack but by using an angle gringer will the hard spots end up hurting the over all knife of jsut make it a little harder to shape mayby?