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My mother had her original wedding ring melted down and formed into a new combo wedding ring/engagement ring. You could melt the metal down and have a new ring formed, that way some of the nicks would come out as well. That way the ring will still be his grandfather's, but it will also be like it's a special ring for the two of you, because it will be slightly different. You could always have a higher karat gold added as well, just to up the quality and lower the brittleness as well. If you have a great jeweler, just talk to him/her and see what they suggest. They would be more qualified to know what they can do.
Well. If you melt the ring down, all the nicks will come out. 
Resizing by a half size or a single size is fairly easy; resizing by more generally requires that the ring be cut and material removed or added, which is something that you can often see in the product. Three sizes is a lot. I would just ask your jeweler what he can do, given the age and condition of the ring. If he doesn't feel that he can resize by that much without compromising quality or appearance, he will let you know.
At the current price of gold, people are taking gold jewelry in to sell - to be melted down and the metal reused. You can absolutely have the ring melted, the gold content adjusted if you like, and a new ring made. Your jeweler should be able to design the new ring to look like the old one. You can consider it the ultimate in refurbishment - essentially the same ring, made of the same gold, but completely new again.
I think the melting down is a good idea. On some bridal show I saw (I can't remember which one since I watch so many) the bride and groom had both lost their fathers. So, they took a piece of jewelry belonging to each father, had them melted down together, and used the metal to make their wedding bands. I thought that was a touching and creative idea.
img0.jpg (38.2 KB, 59 downloads) 2 years old
I had a similiar issue. My E ring was my FI's Grandmother's ring...and boy did his grandmother have big fingers! Her ring size was an 8 and I'm a 4-1/2, plus they had their initials and '44 the year they got engaged enscribed on the inside. We took it to two places to get resized however the first place said they could not save the inscription without altering the size...so off we went to another place. Not only did them resize it down, they kept the inscription and the Platium marking on the band, and gave us the extra peice so if our future grandson needs to alter the ring he has the original material to do so. The ring is absoulutely stunning and we are glad we looked elsewhere.
Our advise...do not settle...there our honest jewlers out there. Do the ring justice and take the time to find someone who takes pride in their craftsmanship and cares for the ring as much as you do.
Damask.jpg (25.3 KB, 214 downloads) 2 years old
Just as an update. We took the ring to our jeweler and we were both pleasantly suprised. They resized (down 3 .5 sizes), buffed the gold and reset the beading for $38.00! The ring looks almost brand new. Up close you can tell it is a little worn but FH is so happy and proud to be wearing his grandfather's ring.
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FI grandmother gave Fi his grandfather's wedding ring over Easter. FI is deeply touched and wants to wear it as his own. I love this idea because the stone in my e-ring belonged to my grandmother.
My only concern is the ring is about 3 sizes too big for FI. I know metal gets brittle as it ages. I figure the ring must be about 25-30 years old, 10k yellow gold and has been worn hard (there are nicks and scratches all over it). Does anyone have any experience/advice on resizing an older ring? We have a great jeweler but I am so scared that FI has been set up for a heartache.
Or any ideas on how he can enjoy the ring if it can not be resized?