Andrew, I watched the video and it was informative. I will be making a new back spring for this one. I'm guessing that the process is to heat treat the back spring and get the fitment right and then heat treat the blade? I was trying to get everything right prior to heat treat.
What I do after scribing the pattern as shown in the video, is cut the spring out, leaving a small amount of extra material on the back of the spring, as well as leaving the end that mates with the blade just a little longer than the pattern. I also drill my back pin hole in the spring as the pattern dictates.
By this point I normally also have the blade cut with a pivot hole drilled, and a nail nick cut in. The blade is cut exactly to the template EXCEPT that I leave additional material on the kick and the very bottom of the tang. The notch that the spring will fit into is cut precisely to the pattern and will serve as the "0" point for my rise and fall indicator, if that makes sense.
Once my blade and spring are "rough cut" as mentioned above, THEN I heat treat both, and go through temper cycles as normal. After the blade and spring are hardened, I will "rough assemble" them onto one side of the handle, pinning the blade, and the center of the back spring into place. I can then mate up the spring and blade and scribe the exact length I'll need for the spring. This is taken to final dimension (CAREFULLY) on my belt grinder. This video shows that process a little better, although IIRC, the ending got screwed up somehow during upload. It should still be enough to give you a good idea.
[video=youtube;FA481oy1FMs]https://www.youtube.com/watch?v=FA481oy1FMs[/video]
Once you get a good tight mate/fit, you can spring temper your spring (actually this can be done right after heat treat as well), and then start working on the rise and fall. I think I cover that some in the next video.
At some point in the hopefully not so distant future, I think I'm going to try and redo that series of videos with a little more detail and better camera angles. Hopefully these are enough to help.