Sam,
I meant to post back on this thread when you put it up, but forgot to.
I make those Frederick's crosses as demo items (and for sale) at forging demos.I do one additional thing that really makes them unique. ( They also make fantastic gifts)
I drop the spike (at forging temp) in the 3/4" hardy hole and forge the head flat ,before starting to open the slits. When done, the cross stands on the flat surface. It even makes the base of the cross have a mound with a step to it. This can be done on the post vise,too, but I prefer to use the hardie hole. I'll go out and forge one this afternoon, and post a photo after Easter Services.
Some other tricks:
Make two sets of tongs. One that holds the head, and another set that hold the square while going over the head.
Make the cut toward the head from the back side of the head (the side that has the smallest lip). This way the base will project out the front side of the cross, and the best surface ( the one without the scallop cut) will be forward.
After flattening the head open the cross like this -
Bring the spike to a good heat and stick the tip in the hardy hole ( or the post vise) bending down to open up the slit toward the head. Bend to 90 degrees. Put the hot cut in the hardie and open up the slit from the tip on the edge.Tap down to open this slit, remove the hot cut and stick the top piece in the hardy hole, bending the top up fully.Moving to the anvil surface, open flat both slits. This can all be done in one heat, two if you are not used to the procedure.
Make a texturing hammer out of an old brick layers, small ball pein, or machinist's hammer. It should have a 3/4" cross pein shaped tip , about 1/8" thick,that is slightly rounded (a chasing/raising hammer), and a small ball pein ( about 1/2" round) on the other end. After the cross is open and straight, go over the surfaces with this hammer. It will texture the metal to look like old wood, and hides the saw marks.
Round off the top end to match the side arms of the cross a bit more. It is more aesthetically pleasing.
Stacy