Well, we bit the bullet and cut some spurs today, Bash's and Aubrey's. Bash's were about 4" long and looked like crossed scimitars. He was easy. His are long and narrow and we took about an inch off each so he still has weaponry, but they don't hook each other.
Aubrey, little jerk D'Anver that he is, turns dark purple if you try to catch him, but he only weighs about 20 oz and his spurs are thicker than Bash's and curve out and downward, so they were touching the ground when he walked. It's always a choice between him maybe dying in my arms from stress or just sitting on those wicked long things and not being able to walk. The chase was on in the pen, Tom trying his best to be quiet and easy with the little lunatic. He finally got him cornered and picked him up, whereupon I realized he was entirely missing a spur! He apparently had hooked it on something during the chase and the tiny pointed inside was sticking out, all bloody-looking. I said to give him to me and I'd get the DE to dust it to stop any bleeding (works better than blood stop powder) and of course, Aubrey bit me, but we got to the other spur and cut off about an inch; should have been more, but at least it's only the one now. Poor thing's leg was obviously painful the rest of the day. He stood around one-legged all day long.
I found the actual spur in the tray of the PVC feeder, probably he caught it on the edge of the opening and just pulled it cleanly off the root. Tonight, Aubrey is sitting under the roost, too much in pain to fly up there, so I got some straw and tried to gently tuck it around him, which normally would send him bouncing off the walls to get away from me, but he didn't even move so I know he's really hurting. Maybe he strained his leg when he caught the spur on the edge of that opening. Since he didn't run, I pushed the straw closer around him and lowered a heat lamp so he is not so cold on the floor while everyone else is up on the roost.