All language subtitles for Forged.In.Fire.S10E10.BTU-Mastering.the.Mystery.480p.Eng

- Here in The Forge,
we put hundreds

of smiths to the test.

- It's hot in here.

- But only a select few
have proven themselves

time and time again,
remaining undefeated.

Now, three of our most
decorated champions

will put their perfect
records on the line

and go head-to-head
against previous

"Forged in Fire"
winners in some

of the most
heated battles yet.

- This is a living nightmare.

- Everything's
right now,

if you know what I'm saying.

- Will anyone have what
it takes to finally...

Oh!

Beat the unbeaten?

- My name is Jay Replogle.

I first competed
on season three

and became a champion when I
made the German Zweihander.

Being a champion has
allowed me to grow my craft

and become better
over the past six years.

I'm coming back
to test my skills

against another champion,

and then possibly

face another champion.

Hopefully, I'm ready.

- I'm Trevor Jenkinson.

I'm a returning champion
from season seven.

I made the war scythe
on the Halloween edition.

Since I've been on the show,
I'm in nursing school

right now, and that's
taken up the majority

of my time the last two years,

But I definitely know more

than when I first competed,

and I'm really excited

to defend my title.

- Champions, welcome back
to The Forge, gentlemen.

You guys are about to take part
in an intense bladesmithing

competition that's going
to test all of your skills.

Now, to start things off,
it's just gonna be the two

of you in the first round
going head-to-head

in a five straight hour
bladesmithing round.

Now, when that
five-hour round is over,

the judges will step in
and test your blades

and ultimately decide which one
of you has impressed them

the most and will be moving
into the second round

of competition.

Now this is where
things get interesting.

In the second round,
you'll be going toe to toe

with one of our titans
of The Forge

because this is
"Beat the Unbeaten."

Now, if you have what it
takes to beat your first round

competitor and one
of our unbeaten champs,

you will go home with
your second "Forged in Fire"

champion title,
but also a check for $10,000.

- I love the challenge of
facing an undefeated opponent,

but it's going
to be super tough.

- Now in this round,
you're going to be building

a signature blade
in your signature style.

All that we ask is
that they measure

between 11 and 13 inches.

In order to do that,
gentlemen, you're

going to need what's under
that cloth on your anvils.

So do us a favor
and take that cloth off.

All right, what you guys
are looking at there

is 80CrV2 high carbon steel.

Now, as you look
at that steel, guys,

you're probably noticing
it's not enough to make

an 11- to 13-inch blade.

And that's because we want
you to add it to this...

Canister Damascus.

Now what we want you to do
is choose your materials

and make a canister.

You're then going
to use that billet

as the cladding
on your 80CrV2 to make

your San Mai signature blade.

- I've never made
this type of Damascus before.

I've practiced canister
and I've practiced San Mai,

but I've never
combined the two.

I'm a little bit nervous
going into this.

- Now, when
the five hours is up,

the judges are going to step in
and test your weapons,

first for strength and
durability in an antler chop.

And then they're going
to check your edge retention

and sharpness
in a Tatami mat slice.

You've only got five hours
on the clock

to complete this challenge,
so good luck

because that time starts now.

- You know,
it's interesting that both

our contestants here--

Jay I remember
from season three

and Trevor from season seven.

So what have they done since
then to get to this point?

Now Jay here, if you didn't
know, he's been in a cave

and he just came out,
I'm ready.

I've been doing nothing
but making blades.

- It feels good coming back
as a champion.

The first time I competed,
it was fairly difficult.

I was up against some
really good guys.

Nerves and all that
kind of take its toll.

But now I think I could come
back and do a little better.

- Now Jay made the Zweihander,
which,

at the time in season three,
was the largest weapon

I think we'd ever done.

- Yeah, he comes in here and
hears 11 to 13, he's like,

pfft, got it.

- My biggest concern is
having to make a canister.

When I found out I was
coming on "Forged in Fire,"

my buddy was like,
you've made canister, right?

And I'm like, no,
I actually haven't because I

hate the way it looks.

And of course,
"Forged in Fire," they know.

They read your mind somehow,
and your greatest fear

comes true on The Forge floor.

But I should be
able to pull it off.

- All right,
first things first.

These guys have
to get a canister going.

We've got fishhook,
we've got bike chain,

and we've got chainsaw blade.

What would you be going for?

- I think fishhooks.

It makes a really
cool pattern, and it's

a finer thing so the welds
are easier to get going on.

- The material I choose
to put in my can is fishhooks,

and the reason is
there's no cleaning.

All the saw blades
and the chain

both have oil
and grease on it.

Fishhooks, brand new,
clean, perfect--

just dump them in.

- Now we've seen canister
done and stripped

in 20 minutes, right?

This is a little bit
more difficult than that.

They've got two
forge welds to do.

They've got to forge
weld that canister,

they've got
to prep the canister,

draw it out, cut it,
and then do another

forge weld on that 80CrV2.

So it really ups
the ante and the difficulty

of this challenge.

Well, right off the bat, it
looks like one of our smiths--

Trevor's decided
to grab the White Out.

So he's planning on
removing the can.

Now it wasn't a requirement.

Unnecessary step.

- I mean, the option of taking
the can off is one thing,

but you could draw
that steel out

and just grind the can off one
side and then do your restack.

- I think
the White Out is going

to help me in the long run.

I'll be able to peel this can
off, I'll have a clean billet,

and I'll be able
to see any problems

that my billet has with it.

So I won't have any cracks
if we get to testing,

and I've got a big old gap
in between something.

I'm going to let this
White Out dry with just

the air because
the last time I competed,

we had to make
a pretty big knife

out of a bunch
of Damascus plates

that had been abandoned.

I put the White Out
into my can, I set it on fire.

It was not supposed
to do that.

I should have just
let it dry, but it

ended up making my cans stick.

And I spent the majority
of my time peeling that off.

- Trevor cooked his White Out
before he put his can

together, so you
notice that can's

not peeling off real easy.

- So I'm kind of happy
that we have to do canister.

And that sounds stupid to say,
but I want to redeem myself

and see if I can do it
a little bit better this time.

- You know,
my concern with Trevor

is he's dumping powder
and everything in there,

but I don't think
he's giving it

enough time to really dry out.

- Now, he's making
this paste on the walls

that won't weld well.

It's the main cause
of a difficult can to peel.

- I'm going to start
working on some handle scales.

- So Jay went shopping
in the pantry,

and it looks like
he grabbed a bunch of very

colorful handle material.

- I remember
the first time I competed,

the testing,
it was fairly difficult.

So I grabbed three
layers of the G10

because I think it offers a lot
more strength in the toughness

and durability tests,
and it'll add

a little bit
of cool factor to the knob,

having the triple colors.

- The nice thing about
Jay making his own scales

is that it pulled him
away from his forge.

He was busy working
on that, and he's

allowing that canister
to really heat up.

- Ah.

- My can took the heat.

I'm going to run to the
squaring dice on the press

and just compress it
on all sides.

- Trevor's going
for his first press.

- Is he actually getting
it up to a high enough

weld temperature?

Or did he get the core even
to the weld temperature?

- He's glowing pretty good,
but it's not at that,

you know, 1,800-plus
welding temperature

that we want to see.

- I'm worried
about being too aggressive

with this can right now.

If this powder isn't
at welding temperature

and I start pushing
and pressing,

it's almost like trying
to make sand castles

without any water.

It's not going to stick
to itself at all.

It's just going to crumble.

And if I push it up too far,

it'll squish out
a little line of metal

going all the way down my can.

So that could cause
inclusions,

cracks, fissures.

Anything like that, it could
really mess up my knife.

- So I wonder how
long he's going

to wait to peel that thing.

- I'd like to see him
do at least one

more pass until
the large dies are touching.

You're reducing
the entire canister,

and it should be
consolidated by then.

- I've gone over
my can a few times now.

I think my billet's is solid.

I'm hoping that I'll be able
to tap my billet out.

We're going
to see how that goes.

- I've got my weld set.

And I can start drawing
out the canister.

- I think that Jay's
at a spot now he can run over

to Big Blu on the next pass.

- Yep, that's the plan.

- Because he's not
trying to peel this can.

- I mean, that's
a 20-minute advantage.

- My plan is
to forge a canister,

then three-stack it, then
build a tall, narrow billet

to compress
and draw out to a blade.

It's quite important that
everything's the same size.

If one side is fatter
than the other,

what it actually
will do is push

the 80CrV2 out of the center.

I may not have hardened
steel on the edge

because the core has shifted
over, which would be terrible.

- My can is solid now.

I'm going to cut
the top completely off,

and then I'm going to cut
the bottom completely off.

And I have one
more cut I'm going

to make along the billet.

I'm hoping
that this will make it

so I can just tap
in the middle,

and my can fall
off either side.

- So cutting a slot is kind
of like trying to peel

a banana from the middle.

- Yeah.

- And your banana's all
chewed up at the end.

- Like eating
a burrito sideways.

- Yeah.

- I can see that it's loose,
but it's just not budging.

To boot with that,
I've got little fissures

on one of these corners.

I think from working
on this can so long,

I've introduced cracks.

That's worrying me right now.

I'm hoping one of these
strikes, it'll just fall off,

but I'm just going
to have to keep on going

and see how far we have to go.

This has taken me a lot longer
than I thought it would,

and I'm really wishing for it
to fall off at some point.

And I'm hoping
there's just a little weld

somewhere I'll have to break.

- There we go.
Good to see Trevor switching--

- Perfect.

- Realizing what he
was doing wasn't working.

Now he's using the floor vise.

- All right.

- A nice smile
going on in there.

- There you go.

- It's a boy.
- It worked.

- We questioned the time
he allotted for that White Out

to dry, but clearly,
the recipe was right.

That can peeled just fine.

- I knew he would
do it all along.

- That's got
to be a good feeling.

- I'm happy with how
the can just peels off,

but I'm seeing smaller cracks
along some of these corners.

I don't think I'm going
to be able to grind those out,

so I'm just going to cut
my losses and cut them off.

- Trevor's billet had some
cracking, but now what's left

is kind of like
the dimension of a hot dog.

And he needs to get that
to be 2 inches wide in order

not to lose any of the 80CrV2

- My initial idea
for this knife

is going to be a big
Bowie style chopper.

That is one that sticks out
to me as just a good style

for this type of competition.

- You know, we've been talking
about Trevor a whole bunch

because it's so much
going on with him.

Meanwhile, Jay's over here
just making a beautiful billet.

- I got my San Mai
billet welded together.

I know I've got
to start working

on drawing my blade out.

I intend to make
a traditional Bowie knife

for this first round,
but if things

don't go exactly right,
it's going

to be close to a Bowie knife.

- Jay is in a really good spot
with that second billet

all welded up.

He's already cleaned
the edges up.

- The Bowie knife I'm making,
it's a knife I make a lot,

and so I can almost
make it in my sleep.

And I'm trying to shape
that steel to the size

that I need it to make
the knife that I want to make.

- All right, guys, two hours
down, three hours left.

- I've got the length and the
width on my billet sorted out.

I've got it cleaned up.

I've got it cut in
the middle, and I'm

going to stick these two
pieces onto that 80CrV2.

- I think the big problem
now is that Trevor's platen

steel is looking so thin.

And if you try to bring up
the forge weld,

some, like, foil on top
of a big chunk in the middle,

it goes all over the place,
and it's

just not enough meat there
to get a good forge going.

- Where Trevor is right now,
what might be a good idea

is to take what he's got,

cut it, clean it, double it
over, and fuller that out.

- You know, I'm really
hoping for Trevor's sake

that this forge weld goes well.

- Oh, this is where
things can go really bad.

This weld doesn't take,
or it falls apart

when he's shaping the tip
or anything like that,

that'll be catastrophic.

- I can't restart now,
so I really need to be

careful with this billet.

- Holy smokes.

- We're about two hours
into the competition right now.

It looks like Jay has
a blade starting to take shape.

And on the other side
of The Forge,

Trevor seems like
he's a bit behind running

into some issues.

- I'm really nervous
about that billet,

so I'm going to take
my time on this.

- Oh, Lord.

All righty.

It seems like these sides
are stuck on good.

I don't see any cracks.

I don't see any inclusions,
anything like that.

It's a big relief.

- Oh, it looks like Trevor's
a little bit happier.

His smile is starting to come
back, his lips are curling.

- I've really got to get going.

It looks real nice.
- Thanks, bro.

- Jay's getting really
close to a quench here.

- As I'm heating the blade,
getting ready to quench,

I keep thinking it's too thick,
it's too thick because

the one thing that can go
wrong with a super thick blade

is it won't harden correctly.

But the clock is ticking.

I need to quench my blade.

- Oh!

- Jay's in the oil.

- Nice.

- There's still a lot
of meat left on it,

and so my main priority
is hitting the grinder,

shedding the weight,
and getting

it down to a usable size.

- So these guys have five hours
to work on the entire blade,

but Trevor has to get
this thing quenched

if he has any hope
of getting to testing.

- Looking at that clock,
it's really bugging me.

I've got to get going
if I want this quenched.

I'm trying my best to get
this knife up to temperature.

And I'm seeing some places
at the tip that are too hot,

and I don't have time
to really cool it down.

I've got to quench now.

- What on Earth
are you waiting for?

- If this quench doesn't go
good, I'm pretty well done.

I'm going to cross
my fingers and my toes

and hope everything goes well.

- I guarantee you
that blade is hot right now.

- That's hotter than his steel
was when he was welding.

- Probably.

- Hoping there's no warp
because he's got

no time to deal with it.

- It doesn't seem
to have any extra cracks

or pieces hanging
off of it, so I'm

feeling all right about it.

I just have a lot
of grinding to do.

- All right, bladesmiths,
you guys have an hour left.

- So my handle fit up
is really important

because I know how
David and those guys

hate a huge, overly big handle.

And if it doesn't feel good,
if it's not comfortable,

it's not going
to perform well.

- Jay's got a finger
weld on his handle,

and he's got the giant swell
at the base of the tang.

Is that not good enough?

- It's an aesthetic choice,
but it is important

that it's not 1/4 inch off.

You can put it
in the wrong spot.

I'm looking at this blade,

and I see
horrible delaminations.

I thought I've gotten rid
of all the delaminations,

but they've really spread.

At my home forge, I'm kind of
a perfectionist with my knives.

I want them
to look really nice.

I want them to look
how I envision them.

That's going
to really mess with me

here because I'm not
going to get the chance

to make it look how I want.

So I got to put that behind me
and just focus on getting

something that works.

- This is what
he's stuck with.

So delaminations or not,
he's stuck with his blade.

- It's looking a
little mangled, but--

- Yeah, it's got a little bit
of thickness to it.

It's about 3/16, it can deal
with a little bit of grinding

and still come out OK.

- I want to chase
these delaminations more,

but I've really got
to get a handle on.

The judges aren't going
to accept it without something

to grab onto.

- We're under ten minutes left

in this "Beat the Unbeaten"
competition.

Jay's moving along.

- My stacked handle scale
is fitting nice.

So I've got pommel swell
on the back,

but it's still
overly big handle.

I need to speed up
the process, or I'm not going

to be able to be done in time.

5, 4, 3, 2, 1.

Gentlemen,
turn off your machines.

Put down your tools.

This first round is now over.

- I feel really
good about my blade,

and I think the judges are
going to be really surprised

that I even got one to them.

So I'm proud of that.

- All right, bladesmiths,
welcome to the strength test,

the antler chop.

Jay, you're up first.
Are you ready?

- Yeah.
Let's do it.

- All right.

- Testing is always
nerve-racking.

You know,
I'm confident in my build.

I think everything went OK,
but you never

know until it's tested.

- All right, Jay, well,
start up here at the edge,

I don't see any issue.

It's still got
a nice fine edge to it.

The handle is comfortable.

I would have liked just
the tiniest bit of refinement

right here.

It's just a little fat
on my ring finger,

but the retention
on it is really good,

the indexing is great, and
the edge held up really well.

Nice job.
- Thank you.

- All right, Trevor,
you're up next.

Are you ready?
- Absolutely.

Give it hell.
- All right.

- My number one
fear is chipping.

That heat treatment
wasn't my best,

and I'm really stressed
about what the antlers

are going to do to my blade.

- All right, Trevor, we were
watching your heat treat

that you did on this,
and it was really rushed,

and it was very hot.

And I was nervous
that this was going

to be a very brittle blade.

- Me too.
- But the edge held up great.

It's amazing.

But I can still see
some delaminations.

My big problem
is that on this side

there's a delamination
that is large enough

that a piece
of antler is actually

wedged up in the delamination.

Moving on to your handle, it's
a little on the bigger side.

There's about a 1/4 inch, 3/8
of an inch too much handle.

But all in all, man, nice job.

- Thank you.

Appreciate it.

- All right,
champion bladesmiths,

congratulations for making
through that strength test.

This is the sharpness test,
the Tatami mat slice.

- Jay, you're up first.
You ready for this?

- Yeah, let's do it.

- All right, Jay, let's talk
about your San Mai knife.

First up, I like the profile.

I like the way it just
matches and glides

right all the way to the tip.

It's a handsome,
nice design you have here.

Your handle construction,
it just happens

to fit my hand perfectly.

Now, the way you
have your grinds,

it allows to cut cleanly
through the Tatami mats.

Overall, your weapon,
it will cut.

- Thank you.

- All right, Trevor, your turn.
So are you ready?

- Yes, sir.
- All right.

Let's do this.

All right, Trevor, I'm really
impressed that you were

able to pull this off
despite all the troubles

that you were having.

This blade right here performed
very well because the edge

is still very razor sharp.

Now, you still have
a delamination there that it

took during the strength test.

But it cut cleanly.

Overall, your blade, it'll cut.

- Thank you, sir.

- Well, gentlemen,
I got to say,

it's been a pleasure
watching both of you guys

work over the past five hours.

But, unfortunately,
we can only bring one of you

into the final round
to face off against our titan.

The bladesmith
leaving The Forge is...

Trevor.

Unfortunately, your blade
did not make the cut,

and Doug's going
to tell you why.

- Trevor, I have
to commend you.

Because despite all
the problems you had,

you turned in a blade
that performed

very well in our test.

But your blade is the only
one that took some damage

during our strength test,
and that's the reason

why you're not moving forward.

- Yes, sir.

- Well, Trevor,
obviously nothing can

get that smile off your face.

It's very evident
you love what you do,

and it's been
a pleasure watching you

work at your craft.

But unfortunately, your time
here in this competition

has ended.

But before you step
off The Forge floor,

we'd all love
to shake your hand, man.

- Yes, sir, it was a privilege.
Thank, y'all.

- Thank you.
- It was really awesome.

- Good job, brother. Good job.

- I may not have won,
but this has

been an awesome experience.

And I'm really happy
with how I did.

I'm not sad about going home.

I'm really kind of pumped up
I get to take a nap.

Jay, you did awesome.

And I am just wishing
you the best of luck

going into this next round.

Whoever you're up against
is going to need it.

- Well, Jay, you are
the epitome of slow is smooth

and smooth is fast.

Through the whole first round,
you kept your head down

and it paid off.

Welcome to round two.

Now, in order to take home
the $10,000 check

and your second "Forged
in Fire" champion title,

you're going to have
to beat an unbeaten competitor.

It'll either be gladiator
of The Forge Jesse Hu,

super champ Collin Sage,

or our very own judge
Ben Abbott.

- I really don't want
to see Ben Abbott.

Pretty sure
he could be a Superman.

I don't think that I
can actually beat him.

- You ready to find
out who that is?

- Oh, yeah.

- All right, man,
you are going to have to go

toe to toe with this guy.

You know what,
that's my mistake.

Your competitor's not
coming out that door.

You're going to have
to beat our judge

who has an unbeaten record,
the most wins

in this forge, Ben Abbott.

- Oh, boy.

What's going on, man?
- Hey.

Good to see you.

- I see you smiling over there.

Was he your first choice?
- No!

- Ben, welcome back
to the competition, bud.

- I think every time I do
one of these competitions,

the stress level goes up.

I think Jay is
a really good competitor,

so winning is not a guarantee.

- You two are going
to be competing against

each other over
the next eight-hour

weapons building competition.

Now, the choice of weapons
is not up to us.

Jay, because you
won the first round,

I'm going to open up
our "Forged in Fire" vault

and give you access
to all the weapons in there

that were built
by previous champions.

And you get to select one
of them to build against Ben.

Are you ready?
- Oh, yeah.

- All right, let's do this.

- Wow.

All right.

Going up against Ben
is going to be super tough.

So I'm going
to pick a weapon that

would be a challenge for him
hoping that it'll give

me a better advantage.

- Great choice.

All right, Jay, you chose
the Medieval Sword of Mystery.

- Hmm.

- The Medieval
Sword of Mystery has

puzzled the world
since its discovery

in England back in 1825.

Believed to date back
to the 13th century,

it earned its name
for the mysterious inscription

on the blade that
to this day, no one

has been able to decipher.

Smiths in the
"Forged in Fire" arena

have also attempted
to crack this mystery back

in season eight,
but a parameter failure

cost one competitor the title.

Now this blade comes with its
own very specific parameters.

Your swords will
have to have a blade

that measures between 28 and
30 inches from tip to guard.

Now, down to the hilt, you
need to have a cruciform guard

and you need to have
a disc-shaped pommel.

Now this is called
the Medieval Sword of Mystery

because it's got
this inscription on it

that nobody can decipher.

In the spirit
of this competition,

we don't want that inscription.

We want your blades
to say "Forged in Fire."

All right, Jay, you have
one more decision to make.

You not only got
to choose the weapon,

but you also get
to choose the technique

that you and Ben
will have to use

in order to make this weapon.

You got anything in mind?

- Yeah, I think we should
do a raindrop Damascus.

- Mm, all right.

Now, gentlemen, we have put
eight hours on the clock.

Good luck.

Your eight hours starts now.

All right, we've got
Ben going against Jay.

They've got to make
the Medieval Sword of Mystery.

It's a very large blade.

They've got to do it
in raindrop pattern Damascus.

- Welding!

- So Jay picks
the Medieval Sword of Mystery.

He also picks
raindrop Damascus.

So I decide I'm going to get
23 layers of 1095 and 15N20,

forge all those together.

Then I can cut my billet
into six pieces,

and stack three on top,
80CrV2 in the middle,

and then three on the bottom.

I feel like that's
going to give a really

nice raindrop pattern,
something that

stands out and is visible.

- This is why
he has the most wins.

Look at his face.
We're eight minutes into it.

He's running.

- Facing off against Ben,
with that kind of record,

it's a tall order.

Welding!

My biggest concern right now
is, of course, the clock,

but I'm just trying
to get this thing

together as fast as I can.

- I think every time I do one
of these competitions,

the stress level goes up.

And this sword makes
this even worse.

It's just so much to do,
and I'm just nervous that I'm

not going to have enough time.

- Ooh, that's a biggun'.

- For me to get
a good raindrop pattern,

I'm going to cut
and restack my billet to end

up with 139 layers total.

OK, welding!

- One thing I've noticed is,
when you guys are competing,

you do a lot of what
you say at the table

while you're out
working on the floor.

Ben's no different.

He talks about pace.
He talks about speed.

He talks about multitasking.

And he's sprinting.

- I'm right on track
for where I want to be.

Here we go.

Looking good.

- Jay, Ben, gentlemen,
you guys have six hours left.

All right, here we go.
Jay on the press.

He's going nice and slow.
Easy task.

- Jay's stacked so tall,
and that's where

you've got to be careful.

But, man, it's taking forever.

- Yeah, it really is.

- In a competition,
usually I have

a plan that I'm sticking to.

That's why I go really slow,
really easy.

Draw it out.

Make sure everything's
really even and nice.

Beautiful.

- So Ben's got his
final billet drawn out.

This is going to be a
really long process.

It seems like a pretty
straightforward blade,

just double-edged straight
blade cross guard.

But raindrop is going
to add a ton of time.

- Oh, my gosh.

This is the fun
stuff right here.

- It's important
to not draw your billet

to its final length before
putting the raindrop pattern.

Because in order
to expose the pattern,

I need to drill in some
divots all along the blade

and then hammer
those divots flat.

- Holy cow, Ben put
so many raindrops in that.

- Raindrops?

More like
a torrential downpour.

- I'm hoping
it's going to turn out well.

There's a lot
of other steps in this,

but I think I'm on track.

- Now, we're almost halfway
into the competition already,

and both Ben and Jay have
a ton of process left

to do if they're
going to have any hope

of getting this blade done.

- Instead of cutting my billet
into little bitty short pieces

and then restacking my billet,
I decided I'm going

to do the hot fold method.

Whoa, Nelly.

It saves a lot of time.

You can produce a high
layer helm super fast.

Whoo!

- That Z fold requires so
much cleaning of the material.

- Oh, he didn't clean it?

- This could be a problem.

- Yeah, it looks like Jay's
going to be relying on flux.

- The problem is fluxing metal
that already has forged scale

on it, the flux
is going to keep

forged scale from building up.

- But it was already
there to begin with.

- Right.
- So this is critical.

- .
Oh, man.

- Oh, guys, it's not working.

Jay's billet is opening up
on the press.

- Well, I'm panicking.

If I can't get
this billet to stick,

I could be going home.

- This next heat
is the do or die.

If it doesn't stick,
he's in trouble.

- Now we're almost halfway
into the competition already,

and both Ben and Jay have
a ton of process left

to do if they're
going to have any hope

of getting this blade done.

- .
Oh, man.

- Oh, guys, it's not working.

Jay's billet is opening
up on the press.

- Well, I'm panicking.

If I can't get this billet
to stick,

I'll probably be trying
to flag down a taxi...

And go home.

Try this damn thing again.

Hopefully, I can just
put a lot of flux

on it to get it to stick.

- This next heat
is the do or die.

If it doesn't stick,
he's in trouble.

- Got it!

Whoo!

I got it to weld.

Thankfully, it worked out.

- So Ben's getting ready
to do his quench.

- All right, here we go.

- All right,
3 hours and 15 minutes left.

Ben's now quenched.

- Looking good.

It looks straight to me.

Time to go get to work on
the pommel and the crossguard.

- I feel like I'm struggling
to keep up with the pace

that I need to keep up.

I peeked over at Ben, and the
way he was running around,

I thought he might be
building a spaceship.

When you're going
up against the best,

you got to get crafty.

- No way.

He's making a raindrop die.

Smart move.

- That's going to speed up
this process tenfold.

Yeah, we were talking
about the raindrop

being the most time
consuming part of this build,

and he's just knocked
a ton of that process out.

- Hey, OK.

I got my pommel
and the guard all done.

Now it's time
to put in the lettering

so that I can go to the edge.

- What's going to
be interesting is how

they're going to be
putting "Forged in Fire"

down that blade.

- There's two basic
ways to do it.

One, they could engrave it.

It's what I did.
Worked out great.

The other way is to use,
like, a nail polish

and paint on what you want.

Then when you acid etch,
it'll cut away everything

that's not on that resist.

- I'm really worried for Jay.

As he grinds,
he's going to find things

trapped inside
that blade because he

didn't do that cleaning step.

As I'm grinding my blade,
I see

it's got bubbles all over it.

- See, this is what
I was worried about.

- I have to make sure
these delams,

they're only on the surface
and they don't go deeper.

Whoo-hoo!

It's just surface issue,
so it's solid,

but it's not like I
would like for it to be.

Now I got to get
this thing quenched.

- You know, we were worried
about Jay continuing

with that initial billet,
but it seems like he's

moving along with it.

So hopefully, it's working out.

- There's a couple surface
delams that I wasn't able

to completely get out,
but I just have

to go with what I've got.

- There we go.

All right, Jay is now quenched.

- Hard.

The quench went pretty well,
but I hope these little issues

don't cost me in the end.

- Jay, Ben, guys, you got
one hour till testing.

- I pulled the sword
out of the edge,

and bright as day there
is all the letters.

They look amazing.

But right now, I don't have
time to sit and stare at it.

I need to finish getting
my sword together,

and I don't have
much time left.

Jay's a really good
competitor, and I saw him

doing some things
that were really intelligent.

So now it's just going to
come down to how they perform.

- Jay is well on his way.

He's got a fully formed blade.

Now it's just a matter
of getting his handle fit up.

- It's really important to have
the right weight on a blade,

but the clock is ticking.

I need to start working
on putting my handle together

or I may not be able
to finish on time.

- He needs to put
a handle on it pretty quick

and get to the grinder.

He has, by far, the largest
blade out there by volume.

- My plan from the get was
to build a simple blade.

Ben's got a few more
fancy-dancy pieces on his,

and so I think if it comes
down to fit and finish,

he's definitely going
to have an advantage.

But nothing is 100%.

Shew!

Damn.

It's a little bit heavy.

The only thing left to do is
just getting the blade thinned

down, getting
the edge thinned down,

and just bringing that
blade into the final form.

- 5, 4, 3, 2, 1.

Gentlemen,
turn off your machines.

Put down your tools.
This round is over.

- I'm feeling good.

I made a sword
that I'm proud of.

It looks beautiful.

I could have used some
more time on the grinder,

but it feels good in my hand.

We'll see.

- Champions, welcome
to the dynamic KEAL test.

Jay, you're up first.
Are you ready for this?

- Let's do this.

I'm worried about a couple
surface delams that I wasn't

able to completely get out.

So that makes me
kind of nervous.

But anything can happen.

- All right, Jay, let's
talk about your sword here.

First up, when I picked it up,

I was wondering
about the kind of wrap

that you're putting on this,
but it actually works

very well,
and it's comfortable.

Nice job on that.

The pommel does pull back
a little bit on the balance,

but it's still a little
bit forward heavy.

Now, your edge--
those first shots

were very deep
into this pig carcass.

But after the clay pot shot,

you could see that there was
some type of dulling because

it didn't cut as sharp.

But more importantly, your
weapon, sir, it will KEAL.

- Thank you.

- OK, Ben, your turn, sir.
Are you ready?

- Sure.
- All right, let's do this.

- Going into testing,
I felt nervous.

I've seen them
chip out blades.

I've seen them do
serious damage.

So now I'm just hoping
that my edge geometry

is good enough to hold up.

- All right, Ben, first up,
your handle dimensions

are perfect for my hands.

I also like the work
that you did with your pommel

and your guard.

Now, your edge--same thing.

Your first initial cuts
are very deep,

but after the clay pot strikes,
you can see

where it took some dulling
in the sweet spot

right here.

But it will KEAL.

- All right,
gentlemen, it's time

for our dynamic strength test,

the bamboo and watermelon chop.

Jay, you're up first.

- Let's do it.

After the first test,
I'm worried about my edge.

Because if my knife
doesn't perform

and doesn't cut
like it needs to,

I could be going home.

- All right, Jay, right off,
there's an edge there.

I wouldn't want to be
hit with this thing.

And you can see,
it cut into the bamboo,

and it cut through the bags.

But it's an impact tool
as opposed

to a really slicing tool.

All in all, I think it's
a really good-looking piece.

But as far as the edge goes,
it's just not as sharp

as I'd really like it to be.

All right, Ben,
are you ready to go?

- Do it, Dave.
- All right.

- Good job, man.

- Thanks, man.

- All right, Ben,
first off, beautiful pattern.

- Thank you.
- That really came out well.

You know,
I can see the raindrops

on all the high spots.

That's really nicely done.

It's got a good weight to it.

It's not very heavy.

As far as the cutting goes,
blade held up fine.

It's easy to use,
and it's got a good feel

to it, so nicely done.

- Thank you.

- All right, gentlemen, very
difficult eight-hour round.

We got two blades that survived
the strength, sharpness,

and KEAL test, and now comes
a time when the judges need

to take a closer look
and decide which one of you

is coming out on top.

So if you could please
give us a moment

and step off The Forge floor.

From where I was standing,
it looked pretty close.

Curious what you guys think.
Doug, I'll start with you.

- Boy, these are
very evenly matched.

When it comes to Ben's blade,

I love the overall look.

The weight is so much
better with his blade.

- OK.
Dave, what about you?

- When I pick up swords
in this type,

the main thing
I want to be able to do

is move it
and fight with it.

Jay's weapon is
at least 3/4 of a pound

heavier than Ben's weapon.

And when fighting, for me,
that's a huge game changer.

The blade, it more
smashed the watermelons

than cut them at all.

Literally, I could
run my finger on it.

Ben's blade,
it functions a lot better.

- OK.
Doug, you made your choice?

- A very difficult one.

- Dave, you made yours?
- Yeah.

- All right, I'll call them in.

Gentlemen, this has been
a very exciting competition.

You both performed
extremely well,

so much so that it made
for a very difficult

decision for our judges.

The winner of this "Beat the
Unbeaten" competition is...

Ben Abbott.

Now, Jay,
you fought extremely hard.

You gave us a great blade,
but, unfortunately,

it just didn't
make the cut today.

And Dave's going
to tell you why.

- Jay, this was really close.

Both of your blades took
almost identical damage.

Both of your blades
performed very closely.

So this came down
to the finest of details.

Your competitor just beat you
out by that much with the fit

and finish of his blade.

- Well, Jay, you're clearly
a fierce competitor,

a talented smith.

And before you
step off the floor,

I would love
to shake your hand.

You have fun?
- Oh, yeah.

To not get the win,
you know, that stinks.

But this whole experience
has been great.

We made awesome swords, and it
feels good to say Ben Abbott

just beat me by this much.

- Well, Ben, by that reaction,
I think you're a little bit

surprised,
but congratulations, buddy,

you are currently undefeated
with a record of 10 and 0.

- Thank you, guys.

- How you feeling?
- Oh, I'm amazed.

I'm relieved.

- Well, Benny boy,
your time on that side is done.

Come back over here, bud.

- Any victory is a victory,
but one

against a really talented
smith like Jay

just means that much more.

He was a tough competitor,
for sure.

Keeping the streak
going is amazing,

but I know there's somebody
somewhere that's going

to be a faster draw than me.

And I'm just happy I came
out on top on this one.