:D I surmise from Ford's latest post that he's not eager to jump in here :lol: so I'll contribute a little more. As it happens I was not there to see him forge out the plate but the majority of the work done on this tsuba occurred during the three weeks I spent in his studio this fall.
Jean, apparently you do occasionally see this style of sekigane in early guards. Ford has postulated that it may have developed to contend with the very issue he faced in reworking the earlier guard.
No offense guys, and with all good will, are you actually challenging this explanation? That's what it sounds like. If you've rejected the description of how it was done I don't blame Ford for not rushing to give you further elaboration on the process when you're apparently dismissive of what's been shared so far.
If you find your conjecture compelling why not try the process yourselves? Whether you end up with a larger or smaller nakago ana you'll have a much better understanding of the process than by hearing Ford's explanation.