From some 3/8" bar stock I did a flat grind to reduce the thickness to about 1/4". I did this with a blaze 60 belt on the belt grinder.
Once the pins are in, I can start shaping the bolster to match the tang. I will make them very close at this stage. Once I remove the bolster, I can work the faces to slope them down to the blade.
I am using a blaze 60 to shape the bolster pieces in place.
For the inside round I opted for a 3/4" drum sander which works pretty good.
Once the shaping is done I remove the bolsters from the tang and repin them together.
Once joined up, I shape the two pieces together.
Focus on the front of the bolsters as these are close to the blade and will not be accessible once pinned permanently to the blade.