Hi Jackie, I managed to make a smooth rebatch on my very first try by accident! First off I didn't grate my soap fine enough. I simply used a hand cheese grater and when I measured it I didn't pack it tight like brown sugar. Then I added like 3 times the amount of water that I was supposed to.
Math was never my strong point.
I had it in a double boiler and stirred and stirred and then stirred some more, then started questioning the recipe because I was going for that "rustic" look! When I realized the water problem I dipped out about 1/3rd of it. It was still too soupy but I kept stirring and eventually reduced the water in the batch enough to pour into molds....
did it get smooth? Yes! Mine turned out to be the consistency of MP.
did it take "forever"? seemed like it. I probably stirred and fretted over it for over an hour.
was it soft? Yes, I had to let it sit in the molds for about 3 days before I could take it out and it was very soft.
did it take forever to harden up after unmolding? It's been drying out now for about 3 weeks and it turned out to be fabulous!
would you do it again? absolutely! it turned out to be one of my best facial soaps, a happy "disaster".
I think if you add enough water and cook it enough you can get a smooth rebatch.