Some pictures of the knife would, in my opinion, would be nice to see where the issues are. I've never done the electrolysis, but I've used vinegar, which has worked, but the soak time varies. Two other possibilities; 1) Contact Osborne and see if they might be of assistance and 2) Seek out a pro who might be able to help. From my perspective, if the cost of going that direction is affordable to rectify the situation, it may well be a good approach.
With the later, take a look at Bladeforums.com. If posting another site for help is verbotten I apologize.