1 00:00:06,089 --> 00:00:09,134 [intense rock music] 2 00:00:09,134 --> 00:00:12,179 ♪ ♪ 3 00:00:12,179 --> 00:00:15,307 [country rock music] 4 00:00:15,307 --> 00:00:16,600 ‐ My name is Ryan Dumont, 5 00:00:16,600 --> 00:00:18,769 39, from Fort Scott, Kansas. 6 00:00:18,769 --> 00:00:21,021 I'm as country as country comes. 7 00:00:21,021 --> 00:00:23,440 I seen a gentlemen making blades 8 00:00:23,440 --> 00:00:25,275 at an amusement park. 9 00:00:25,275 --> 00:00:26,693 Decided I could do it. 10 00:00:26,693 --> 00:00:29,696 And I've never looked back. 11 00:00:29,696 --> 00:00:31,657 I'm pretty confident in what I can do. 12 00:00:31,657 --> 00:00:33,700 ♪ ♪ 13 00:00:33,700 --> 00:00:36,537 ‐ My name's Steve Wells. I'm 47 years old. 14 00:00:36,537 --> 00:00:38,121 I spent eight years of my life 15 00:00:38,121 --> 00:00:39,706 riding bulls in rodeo. 16 00:00:39,706 --> 00:00:41,792 I took a bad fall and broke my leg. 17 00:00:41,792 --> 00:00:44,962 And all of a sudden, my priorities changed. 18 00:00:44,962 --> 00:00:46,797 And getting into bladesmithing 19 00:00:46,797 --> 00:00:49,550 really gave me an avenue for creativity. 20 00:00:49,550 --> 00:00:51,385 ‐ My name is Wesley Boone. 21 00:00:51,385 --> 00:00:53,345 I am 23 years old, 22 00:00:53,345 --> 00:00:55,722 and I am a part‐time bladesmith. 23 00:00:55,722 --> 00:00:59,268 I got into bladesmithing through martial arts. 24 00:00:59,268 --> 00:01:02,729 My specialty would be fighting knives. 25 00:01:02,729 --> 00:01:06,066 I like knives that are going to be used. 26 00:01:06,066 --> 00:01:07,609 ‐ Name's Bud Smith. 27 00:01:07,609 --> 00:01:09,653 I'm 65 years old. 28 00:01:09,653 --> 00:01:12,322 I'm from Harmony, North Carolina. 29 00:01:12,322 --> 00:01:14,324 I've made knives for the movies. 30 00:01:14,324 --> 00:01:15,742 I've made them for television. 31 00:01:15,742 --> 00:01:17,619 I got pretty good at it, apparently. 32 00:01:17,619 --> 00:01:18,704 [chuckles] 33 00:01:18,704 --> 00:01:20,163 ♪ ♪ 34 00:01:20,163 --> 00:01:22,291 ‐ Bladesmiths, welcome to The Forge. 35 00:01:22,291 --> 00:01:24,918 You are here to engage in three timed rounds 36 00:01:24,918 --> 00:01:26,670 of edged weapon‐making competition 37 00:01:26,670 --> 00:01:28,088 specifically designed 38 00:01:28,088 --> 00:01:30,048 to test every aspect of your skills 39 00:01:30,048 --> 00:01:31,466 in front of a panel of expert judges 40 00:01:31,466 --> 00:01:32,759 that will tell us which of you 41 00:01:32,759 --> 00:01:34,553 is our next Forged in Fire champion, 42 00:01:34,553 --> 00:01:38,181 leaving this Forge with a check for $10,000. 43 00:01:38,181 --> 00:01:39,391 Let's go ahead and meet your judges. 44 00:01:39,391 --> 00:01:40,684 Now, up first, 45 00:01:40,684 --> 00:01:41,935 two‐time Forged in Fire champion, 46 00:01:41,935 --> 00:01:42,936 Ben Abbott. 47 00:01:42,936 --> 00:01:44,438 Next, historic weapons 48 00:01:44,438 --> 00:01:46,148 re‐creation specialist, David Baker. 49 00:01:46,148 --> 00:01:47,566 And last, 50 00:01:47,566 --> 00:01:49,568 Kali martial artist, Doug Marcaida. 51 00:01:49,568 --> 00:01:51,611 ♪ ♪ 52 00:01:51,611 --> 00:01:53,113 Bladesmiths, here in The Forge, 53 00:01:53,113 --> 00:01:55,073 we've had smiths make knives out of everything 54 00:01:55,073 --> 00:01:57,784 from pinball machines, to cars and tanks, 55 00:01:57,784 --> 00:02:00,162 and even backhoes. 56 00:02:00,162 --> 00:02:03,290 Today, there's no big reveals. 57 00:02:03,290 --> 00:02:06,335 You're gonna be making knives out of something smaller. 58 00:02:06,335 --> 00:02:08,128 Much, much smaller. 59 00:02:08,128 --> 00:02:11,131 [dramatic percussive music] 60 00:02:11,131 --> 00:02:17,054 ♪ ♪ 61 00:02:18,764 --> 00:02:20,140 Gentlemen, what we have here 62 00:02:20,140 --> 00:02:22,643 is a big pile of high carbon steel 63 00:02:22,643 --> 00:02:23,644 drill shavings. 64 00:02:23,644 --> 00:02:25,395 We usually throw these away, 65 00:02:25,395 --> 00:02:27,272 but today, we're gonna ask you guys to get scrappy 66 00:02:27,272 --> 00:02:29,608 and turn these steel shavings into a billet. 67 00:02:29,608 --> 00:02:31,234 From which you will forge a signature blade 68 00:02:31,234 --> 00:02:32,819 in your signature style that is between 69 00:02:32,819 --> 00:02:34,905 10 and 12 inches in length. 70 00:02:34,905 --> 00:02:37,658 ‐ It's a bucket full of trash. 71 00:02:37,658 --> 00:02:39,117 They're pushing the limits here. 72 00:02:39,117 --> 00:02:40,869 ♪ ♪ 73 00:02:40,869 --> 00:02:42,287 ‐ You'll have just three hours 74 00:02:42,287 --> 00:02:43,664 in this first round of competition 75 00:02:43,664 --> 00:02:44,998 in which to complete all that work. 76 00:02:44,998 --> 00:02:46,833 If you make it to the second round, 77 00:02:46,833 --> 00:02:49,169 you'll have a chance to attach handles to your blades. 78 00:02:49,169 --> 00:02:51,546 And then we'll test them for strength and durability 79 00:02:51,546 --> 00:02:53,340 in a trash can stab and chop 80 00:02:53,340 --> 00:02:55,842 and for edge retention in a leather bag slice. 81 00:02:55,842 --> 00:02:58,595 How you choose to design your signature blades 82 00:02:58,595 --> 00:02:59,930 to perform in those challenges 83 00:02:59,930 --> 00:03:01,932 is of paramount importance 84 00:03:01,932 --> 00:03:04,685 and will be taken into consideration by our judges. 85 00:03:04,685 --> 00:03:07,771 Good luck. Your three hours starts...now. 86 00:03:07,771 --> 00:03:11,191 [intense rock music] 87 00:03:11,191 --> 00:03:12,859 This is a canister Damascus day, I'm assuming. 88 00:03:12,859 --> 00:03:13,902 ‐ Yeah. 89 00:03:13,902 --> 00:03:15,195 ‐ It seems like it's a pretty 90 00:03:15,195 --> 00:03:16,613 straightforward challenge; 91 00:03:16,613 --> 00:03:18,115 shove as many of these shavings and bits 92 00:03:18,115 --> 00:03:19,533 into a can as you can. 93 00:03:19,533 --> 00:03:21,993 Throw some 1095 powder in there with it. 94 00:03:21,993 --> 00:03:24,204 Weld it up and then heat and beat. 95 00:03:24,204 --> 00:03:26,623 ‐ Getting the canister packed as tightly as possible 96 00:03:26,623 --> 00:03:29,376 with these shavings and the powders can be tough. 97 00:03:29,376 --> 00:03:30,877 ♪ ♪ 98 00:03:30,877 --> 00:03:32,838 ‐ My plan's gonna be a canister. 99 00:03:32,838 --> 00:03:34,714 I don't know of any other way I can get all 100 00:03:34,714 --> 00:03:36,341 the drill filings put together. 101 00:03:36,341 --> 00:03:38,260 I'm using the White Out. 102 00:03:38,260 --> 00:03:39,928 I know that'll keep the can 103 00:03:39,928 --> 00:03:41,555 from adhering to the metal. 104 00:03:41,555 --> 00:03:45,225 Make it easier to get the canister itself off. 105 00:03:45,225 --> 00:03:46,726 ‐ Bud has grabbed some White Out. 106 00:03:46,726 --> 00:03:48,895 Strategically, what do you think 107 00:03:48,895 --> 00:03:50,522 about that move, White Out? 108 00:03:50,522 --> 00:03:51,481 ‐ It's a release agent, 109 00:03:51,481 --> 00:03:52,482 if it's allowed 110 00:03:52,482 --> 00:03:53,900 to dry naturally in air. 111 00:03:53,900 --> 00:03:54,985 But if you rush it, 112 00:03:54,985 --> 00:03:56,027 it makes it very difficult 113 00:03:56,027 --> 00:03:57,028 to peel that can. 114 00:03:57,028 --> 00:03:57,988 ♪ ♪ 115 00:03:57,988 --> 00:03:59,739 ‐ I'm off to slow start. 116 00:03:59,739 --> 00:04:01,324 ♪ ♪ 117 00:04:01,324 --> 00:04:02,826 ‐ I am very familiar with canister. 118 00:04:02,826 --> 00:04:04,035 That's my go‐to. 119 00:04:04,035 --> 00:04:05,078 ♪ ♪ 120 00:04:05,078 --> 00:04:06,746 My game plan is to get 121 00:04:06,746 --> 00:04:09,040 the White Out in it so I can peel the can off easier. 122 00:04:09,040 --> 00:04:10,750 A hell of a mess. 123 00:04:10,750 --> 00:04:12,252 And I'm getting White Out all over my face 124 00:04:12,252 --> 00:04:13,753 and all over the table. 125 00:04:13,753 --> 00:04:14,921 ‐ I think Ryan actually ate 126 00:04:14,921 --> 00:04:16,256 some of the White Out. 127 00:04:16,256 --> 00:04:18,425 ♪ ♪ 128 00:04:18,425 --> 00:04:20,635 ‐ At home, I would let it dry completely, 129 00:04:20,635 --> 00:04:22,262 but being here, I won't have time. 130 00:04:22,262 --> 00:04:23,764 ♪ ♪ 131 00:04:23,764 --> 00:04:25,098 Ah, [bleep]. 132 00:04:25,098 --> 00:04:26,433 ‐ That White Out is wet. 133 00:04:26,433 --> 00:04:27,684 And now he's pouring powdered steel 134 00:04:27,684 --> 00:04:28,727 on top of that. 135 00:04:28,727 --> 00:04:30,228 Which we know, 136 00:04:30,228 --> 00:04:31,605 the White Out's gonna get stuck to the powder. 137 00:04:31,605 --> 00:04:32,939 ‐ It's the worst of all worlds 138 00:04:32,939 --> 00:04:34,900 because when you mix a slurry 139 00:04:34,900 --> 00:04:37,152 with the White Out like that, it does weld to the can, 140 00:04:37,152 --> 00:04:38,528 but not really well. 141 00:04:38,528 --> 00:04:39,738 It makes it really difficult to peel. 142 00:04:39,738 --> 00:04:41,615 ♪ ♪ 143 00:04:41,615 --> 00:04:44,826 ‐ I got everything packed in it, welded up. 144 00:04:44,826 --> 00:04:46,703 Looks like a cake. You gotta let it bake. 145 00:04:46,703 --> 00:04:48,705 Longer you let it cook, the better off it is. 146 00:04:48,705 --> 00:04:50,624 It's gonna be a solid billet when it comes out. 147 00:04:50,624 --> 00:04:53,335 ♪ ♪ 148 00:04:53,335 --> 00:04:55,420 ‐ I've never done any canister Damascus before. 149 00:04:55,420 --> 00:04:57,923 ‐ Wesley's going for the White Out. 150 00:04:57,923 --> 00:04:59,966 ‐ If you're experienced in removing a can, 151 00:04:59,966 --> 00:05:01,468 it's not that big a deal, 152 00:05:01,468 --> 00:05:03,553 but we've seen it go wrong so many times. 153 00:05:03,553 --> 00:05:06,973 ‐ Ah! Son of a [bleep]. 154 00:05:06,973 --> 00:05:08,725 ‐ Chad starting over a billet. 155 00:05:08,725 --> 00:05:09,935 Come on, K. Keep working. 156 00:05:09,935 --> 00:05:11,812 ♪ ♪ 157 00:05:11,812 --> 00:05:13,939 ‐ If I don't put enough White Out 158 00:05:13,939 --> 00:05:16,149 on the outside, it just sticks. 159 00:05:16,149 --> 00:05:18,443 And that can is a pain to get off. 160 00:05:18,443 --> 00:05:19,736 ♪ ♪ 161 00:05:19,736 --> 00:05:21,196 ‐ Everybody going with the White Out? 162 00:05:21,196 --> 00:05:23,198 ‐ Steve is the only one of our smiths 163 00:05:23,198 --> 00:05:26,660 who didn't bring any White Out over to his station. 164 00:05:26,660 --> 00:05:28,495 ‐ I'm not gonna bother with the White Out. 165 00:05:28,495 --> 00:05:30,539 I'm just gonna go with it. Forge it in. 166 00:05:30,539 --> 00:05:32,374 Try to grind that canister off 167 00:05:32,374 --> 00:05:34,793 when I do the grinding on my blade. 168 00:05:34,793 --> 00:05:36,503 This could be the thing that bites me. 169 00:05:36,503 --> 00:05:38,004 But I'm gonna‐‐I'm gonna take that chance. 170 00:05:38,004 --> 00:05:39,381 ♪ ♪ 171 00:05:39,381 --> 00:05:40,882 ‐ It looks like Steve is gonna try 172 00:05:40,882 --> 00:05:42,843 to force that can lid down into his, uh‐‐ 173 00:05:42,843 --> 00:05:45,345 ‐ Yeah, that's a good idea. ‐ Into his material there. 174 00:05:45,345 --> 00:05:47,097 ‐ Otherwise, you get big air pockets. 175 00:05:47,097 --> 00:05:49,015 Essentially, cold shuts. 176 00:05:49,015 --> 00:05:50,851 ‐ I am not the strongest welder, 177 00:05:50,851 --> 00:05:52,853 but I gobbed it on there good enough. 178 00:05:52,853 --> 00:05:54,980 Now we wait. 179 00:05:54,980 --> 00:05:56,356 ‐ Bladesmiths! 180 00:05:56,356 --> 00:05:57,816 One hour has elapsed. 181 00:05:57,816 --> 00:06:00,068 You have only two hours remaining 182 00:06:00,068 --> 00:06:02,195 to finish your work. 183 00:06:02,195 --> 00:06:03,989 ‐ The tricky thing about canister is 184 00:06:03,989 --> 00:06:06,366 if the forge welds forge and weld, 185 00:06:06,366 --> 00:06:08,535 then I have no clue until I open the can. 186 00:06:08,535 --> 00:06:10,161 ♪ ♪ 187 00:06:10,161 --> 00:06:12,539 As I'm peeling the can off, I see inside 188 00:06:12,539 --> 00:06:14,416 that I'm not in a good situation. 189 00:06:14,416 --> 00:06:15,792 [bleep] 190 00:06:15,792 --> 00:06:18,670 I see scraps and falling out material. 191 00:06:18,670 --> 00:06:21,047 Half the billets was welded and half of it wasn't. 192 00:06:21,047 --> 00:06:23,049 Gotta make a new one. 193 00:06:23,049 --> 00:06:25,552 I have to start over and build a new billet. 194 00:06:25,552 --> 00:06:27,637 ‐ Ryan's starting over. ‐ Yep. 195 00:06:27,637 --> 00:06:30,223 ‐ I wonder what he saw on the inside of his canister. 196 00:06:30,223 --> 00:06:32,017 He started to open and peel. 197 00:06:32,017 --> 00:06:34,519 ‐ So that's 45 minutes gone. 198 00:06:34,519 --> 00:06:35,729 ♪ ♪ 199 00:06:35,729 --> 00:06:37,397 ‐ Ryan is gonna go without 200 00:06:37,397 --> 00:06:39,107 the White Out this time. ‐ That'll be good. 201 00:06:39,107 --> 00:06:42,068 ‐ I don't have time to let the White Out dry properly, 202 00:06:42,068 --> 00:06:43,904 so I'm just gonna pack it full 203 00:06:43,904 --> 00:06:45,614 and I'll grind the canister away. 204 00:06:45,614 --> 00:06:47,574 But first, I have to let it bake. 205 00:06:47,574 --> 00:06:50,327 I can't do anything else but watch the metal heat up. 206 00:06:50,327 --> 00:06:52,704 So I stand there and watch it. [chuckles] 207 00:06:52,704 --> 00:06:55,582 Come on, you dirty bitch. Heat up. 208 00:06:55,582 --> 00:06:57,917 Once I get it heated up to forge temperature, 209 00:06:57,917 --> 00:06:59,252 and I press it lightly, 210 00:06:59,252 --> 00:07:01,880 till I feel like that it's a solid billet. 211 00:07:01,880 --> 00:07:03,590 ♪ ♪ 212 00:07:03,590 --> 00:07:05,759 ‐ Not enough pressure going into that press. 213 00:07:05,759 --> 00:07:07,260 Bud will never get the compression 214 00:07:07,260 --> 00:07:08,553 to set those welds. 215 00:07:08,553 --> 00:07:10,055 ‐ Oh, look at Bud. 216 00:07:10,055 --> 00:07:11,306 ‐ Wow, look at that. Oh, my God. 217 00:07:11,306 --> 00:07:12,974 That's a lot of powder. 218 00:07:12,974 --> 00:07:14,893 ‐ That has not forged well. 219 00:07:14,893 --> 00:07:16,353 ♪ ♪ 220 00:07:16,353 --> 00:07:19,272 ‐ Hopefully I can cut the end of it off. 221 00:07:19,272 --> 00:07:21,358 Being it's got White Out, 222 00:07:21,358 --> 00:07:25,028 it shouldn't take too much to take the canister off. 223 00:07:25,028 --> 00:07:27,697 ‐ Bud's over here trying to peel a mess apart. 224 00:07:27,697 --> 00:07:30,867 Man, that thing is mangled, meddled mayhem. 225 00:07:30,867 --> 00:07:34,496 ‐ Only thing I can do, hammer like hell. 226 00:07:34,496 --> 00:07:37,374 I had to cut it more than once to get it off. 227 00:07:37,374 --> 00:07:39,918 Finally, both sides basically fell off. 228 00:07:39,918 --> 00:07:41,294 ♪ ♪ 229 00:07:41,294 --> 00:07:43,421 ‐ Oh! ‐ Look at all that sparks. 230 00:07:43,421 --> 00:07:45,048 I'd like to see that billet flux, 231 00:07:45,048 --> 00:07:46,591 brought up to a welding temperature, 232 00:07:46,591 --> 00:07:47,842 and consolidated. 233 00:07:47,842 --> 00:07:49,427 Bud might go with a Big Blu 234 00:07:49,427 --> 00:07:51,304 with one hit and have that billet fall apart. 235 00:07:51,304 --> 00:07:55,183 ♪ ♪ 236 00:07:55,183 --> 00:07:57,977 ‐ Just wanna start compressing things a little bit 237 00:07:57,977 --> 00:08:00,605 before I really get after it. 238 00:08:00,605 --> 00:08:02,148 ‐ I'm really impressed with Steve. 239 00:08:02,148 --> 00:08:03,566 He's got great heat. 240 00:08:03,566 --> 00:08:05,193 He's got great control of the press. 241 00:08:05,193 --> 00:08:06,903 He's the only one who didn't use White Out, 242 00:08:06,903 --> 00:08:10,115 so he's just gonna work with that steel can as it is. 243 00:08:10,115 --> 00:08:11,741 ♪ ♪ 244 00:08:11,741 --> 00:08:13,118 ‐ Big Blu. 245 00:08:13,118 --> 00:08:16,579 ♪ ♪ 246 00:08:16,579 --> 00:08:18,331 ‐ I'm trying to give my canister 247 00:08:18,331 --> 00:08:19,999 a little bit more pressure 248 00:08:19,999 --> 00:08:21,459 to refine those welds. 249 00:08:21,459 --> 00:08:22,961 ♪ ♪ 250 00:08:22,961 --> 00:08:25,213 And then I'm ready to take this can off. 251 00:08:25,213 --> 00:08:27,757 I just try to split it lengthwise. 252 00:08:27,757 --> 00:08:29,676 ‐ Wesley used White Out, 253 00:08:29,676 --> 00:08:32,345 and he used flash dies in order to set the welds. 254 00:08:32,345 --> 00:08:36,182 And I imagine there's a lot of air pockets inside there. 255 00:08:36,182 --> 00:08:39,018 ‐ The vise keeps moving, so I'm fighting the vise 256 00:08:39,018 --> 00:08:42,188 and trying to get this can off at the same time. 257 00:08:42,188 --> 00:08:44,691 ‐ One of the things about this competition 258 00:08:44,691 --> 00:08:46,693 is you gotta know when you try something, 259 00:08:46,693 --> 00:08:48,361 you give it a time limit. 260 00:08:48,361 --> 00:08:50,155 And then if it doesn't work, change strategies. 261 00:08:50,155 --> 00:08:52,741 ♪ ♪ 262 00:08:52,741 --> 00:08:54,534 ‐ I don't wanna be that guy 263 00:08:54,534 --> 00:08:57,620 that didn't even bring a blade to the end of that round. 264 00:08:57,620 --> 00:09:00,707 I'm not gonna get this can off and have time 265 00:09:00,707 --> 00:09:02,292 to finish forging my blade. 266 00:09:04,377 --> 00:09:05,712 Starting over. Starting over. 267 00:09:05,712 --> 00:09:06,963 ‐ Oh, man. 268 00:09:06,963 --> 00:09:08,631 Wesley is gonna start over. 269 00:09:08,631 --> 00:09:10,800 I hope to God he does not use‐‐ 270 00:09:10,800 --> 00:09:13,136 ‐ He has a bottle right by him. 271 00:09:13,136 --> 00:09:14,637 ‐ And he has a bottle of White Out. 272 00:09:14,637 --> 00:09:15,847 I wanna smack it out of his hand. 273 00:09:15,847 --> 00:09:18,892 ‐ Yeah. [laughing] 274 00:09:18,892 --> 00:09:20,810 ‐ So two of our smiths 275 00:09:20,810 --> 00:09:23,396 have opted to start over from scratch. 276 00:09:23,396 --> 00:09:24,606 ♪ ♪ 277 00:09:24,606 --> 00:09:25,940 ‐ This one I'm gonna grind out 278 00:09:25,940 --> 00:09:28,026 a little bit less than I did before 279 00:09:28,026 --> 00:09:30,737 and hopefully that gives me the piece I need. 280 00:09:30,737 --> 00:09:31,988 ♪ ♪ 281 00:09:31,988 --> 00:09:33,364 ‐ I've got my second canister 282 00:09:33,364 --> 00:09:34,908 up to temperature 283 00:09:34,908 --> 00:09:36,910 and hope that it does forge well. 284 00:09:36,910 --> 00:09:38,787 If this one doesn't work out, I don't know if I have 285 00:09:38,787 --> 00:09:41,081 enough time on the clock to do another one. 286 00:09:41,081 --> 00:09:43,458 ♪ ♪ 287 00:09:43,458 --> 00:09:46,586 This time I see the inside, and it's solid welded. 288 00:09:46,586 --> 00:09:49,297 Smash it down a little more and set them welds, 289 00:09:49,297 --> 00:09:51,091 and start putting a point on it. 290 00:09:51,091 --> 00:09:52,217 ♪ ♪ 291 00:09:52,217 --> 00:09:53,551 ‐ Two hours has elapsed. 292 00:09:53,551 --> 00:09:55,428 You have 60 minutes remaining. 293 00:09:55,428 --> 00:09:57,097 ♪ ♪ 294 00:09:57,097 --> 00:09:58,973 ‐ I strike the billet now, 295 00:09:58,973 --> 00:10:00,600 and I hand‐hammer it. 296 00:10:00,600 --> 00:10:03,103 It needs some work, but it wasn't too bad. 297 00:10:03,103 --> 00:10:05,480 ♪ ♪ 298 00:10:05,480 --> 00:10:07,357 ‐ I'm seeing some head shaking from Bud. 299 00:10:07,357 --> 00:10:08,983 ♪ ♪ 300 00:10:08,983 --> 00:10:10,777 I don't know what he sees. 301 00:10:10,777 --> 00:10:12,153 ‐ I got a couple cracks. 302 00:10:12,153 --> 00:10:13,947 I might have to weld and grind them off. 303 00:10:13,947 --> 00:10:14,948 I don't know. 304 00:10:14,948 --> 00:10:16,866 ♪ ♪ 305 00:10:16,866 --> 00:10:19,410 I started to weld off a couple of them 306 00:10:19,410 --> 00:10:21,204 that I thought might give me an issue. 307 00:10:21,204 --> 00:10:23,164 ‐ Bud over to the MIG welder. 308 00:10:23,164 --> 00:10:25,792 It shows there's most likely surface cracks going on, 309 00:10:25,792 --> 00:10:27,710 but no way to fix it if that's the case. 310 00:10:27,710 --> 00:10:30,964 ‐ I don't know how it looks inside of the steel, 311 00:10:30,964 --> 00:10:34,134 but I think the major cracks I got sealed up. 312 00:10:34,134 --> 00:10:36,636 I don't wanna be the first one walking down the hall. 313 00:10:36,636 --> 00:10:39,556 ♪ ♪ 314 00:10:39,556 --> 00:10:41,724 ‐ I get my second piece hot, 315 00:10:41,724 --> 00:10:45,436 and I try to get as much pressure on that as I can. 316 00:10:45,436 --> 00:10:48,022 And then I start cutting it. 317 00:10:48,022 --> 00:10:50,984 I cut off a section, hit it with the punch. 318 00:10:50,984 --> 00:10:52,152 ♪ ♪ 319 00:10:52,152 --> 00:10:53,319 ‐ Come on, Wesley. 320 00:10:53,319 --> 00:10:54,737 ‐ I rinse, wash, and repeat. 321 00:10:54,737 --> 00:10:57,073 ♪ ♪ 322 00:10:57,073 --> 00:10:59,742 And it comes out. 323 00:10:59,742 --> 00:11:01,536 ♪ ♪ 324 00:11:01,536 --> 00:11:04,330 But I'm still anxious that I'm gonna run out of time. 325 00:11:04,330 --> 00:11:06,958 ‐ 20 minutes, bladesmiths. 326 00:11:06,958 --> 00:11:08,376 ‐ I'm trying to not to get too fancy. 327 00:11:08,376 --> 00:11:10,753 I'm‐‐I'm sticking with what I know. 328 00:11:10,753 --> 00:11:13,339 I get my forging out close enough 329 00:11:13,339 --> 00:11:15,258 that I've gotta get this thing in the tank 330 00:11:15,258 --> 00:11:16,342 and get it quenched. 331 00:11:16,342 --> 00:11:18,761 ♪ ♪ 332 00:11:18,761 --> 00:11:20,889 ‐ Steve just quenched his blade over here. 333 00:11:22,515 --> 00:11:23,850 ♪ ♪ 334 00:11:23,850 --> 00:11:25,894 ‐ Pretty straight. Ain't bad. 335 00:11:25,894 --> 00:11:27,854 I've got time to get to the grinder 336 00:11:27,854 --> 00:11:29,439 and get some of that mild steel off 337 00:11:29,439 --> 00:11:31,608 from the can, to where I'm down to the hard steel. 338 00:11:31,608 --> 00:11:33,818 ♪ ♪ 339 00:11:33,818 --> 00:11:35,445 ‐ I'm running out of time. 340 00:11:35,445 --> 00:11:37,488 I've gotta grind down through the mild steel 341 00:11:37,488 --> 00:11:40,575 to get to the hardening steel. 342 00:11:40,575 --> 00:11:42,869 I'm gonna get a good, solid quench. 343 00:11:42,869 --> 00:11:44,370 ♪ ♪ 344 00:11:44,370 --> 00:11:46,623 I'm looking for a salmon color. 345 00:11:46,623 --> 00:11:48,041 It's now or never. 346 00:11:48,041 --> 00:11:49,918 ♪ ♪ 347 00:11:49,918 --> 00:11:51,294 ‐ Ryan just quenched. 348 00:11:51,294 --> 00:11:52,587 Quenched at a pretty good temperature. 349 00:11:52,587 --> 00:11:54,255 ‐ Yeah. ‐ It was a little hot. 350 00:11:54,255 --> 00:11:55,632 ‐ When I pull it out of the oil, 351 00:11:55,632 --> 00:11:57,550 I see there's a slight warp in it, 352 00:11:57,550 --> 00:11:59,052 so I try to take the warp out. 353 00:11:59,052 --> 00:12:00,970 ♪ ♪ 354 00:12:00,970 --> 00:12:04,015 ‐ Five minutes, bladesmiths. Five minutes. 355 00:12:04,015 --> 00:12:06,392 ‐ I have to get a hardened blade. 356 00:12:06,392 --> 00:12:09,646 As to date, I haven't had a blade break on me. 357 00:12:09,646 --> 00:12:12,190 ♪ ♪ 358 00:12:12,190 --> 00:12:14,025 ‐ Bud just quenched. 359 00:12:14,025 --> 00:12:16,319 ‐ I assumed it'd be hard, 360 00:12:16,319 --> 00:12:18,238 but I feel nervous because I know 361 00:12:18,238 --> 00:12:20,448 there was a couple of slight cracks in it. 362 00:12:20,448 --> 00:12:22,450 You know, I wonder if the judges are gonna go for that, 363 00:12:22,450 --> 00:12:23,493 I don't know. 364 00:12:23,493 --> 00:12:27,830 ♪ ♪ 365 00:12:27,830 --> 00:12:29,624 ‐ Wesley needs to quench soon. 366 00:12:29,624 --> 00:12:31,834 ‐ He needs to quench on this heat. 367 00:12:31,834 --> 00:12:34,754 ♪ ♪ 368 00:12:34,754 --> 00:12:36,464 ‐ Hey, there we go. ‐ All right. 369 00:12:36,464 --> 00:12:38,758 ‐ So Wesley has quenched his blade. 370 00:12:38,758 --> 00:12:41,719 One minute! ‐ I didn't see bad warps. 371 00:12:41,719 --> 00:12:43,429 Y'all gave me three hours. 372 00:12:43,429 --> 00:12:46,391 I'm using every bit of time that I can possibly use. 373 00:12:46,391 --> 00:12:49,519 ‐ Five, four, three, 374 00:12:49,519 --> 00:12:51,521 two, one! 375 00:12:51,521 --> 00:12:53,356 Bladesmiths, shut down your machines. 376 00:12:53,356 --> 00:12:55,858 Drop your tools. Stop what you're doing. 377 00:12:55,858 --> 00:12:58,361 This first round of competition is over. 378 00:12:58,361 --> 00:13:00,613 [clapping] 379 00:13:00,613 --> 00:13:03,741 ♪ ♪ 380 00:13:03,741 --> 00:13:05,785 ‐ I didn't wanna be that guy to come up here 381 00:13:05,785 --> 00:13:07,537 and not make it. 382 00:13:07,537 --> 00:13:09,789 So I'm relieved, but I'm still anxious 383 00:13:09,789 --> 00:13:12,041 to see how this blade is gonna perform. 384 00:13:12,041 --> 00:13:13,918 ♪ ♪ 385 00:13:13,918 --> 00:13:15,378 ‐ All right, gents, 386 00:13:15,378 --> 00:13:16,504 in this first round of competition, 387 00:13:16,504 --> 00:13:17,880 we asked you guys to make 388 00:13:17,880 --> 00:13:19,882 signature 10 to 12‐inch blades 389 00:13:19,882 --> 00:13:24,470 by using scrap high carbon steel drill shavings. 390 00:13:24,470 --> 00:13:26,431 Now it's time for the judges to take a closer look 391 00:13:26,431 --> 00:13:27,724 at what you've done. 392 00:13:27,724 --> 00:13:29,142 Ryan, you're up first. 393 00:13:29,142 --> 00:13:31,519 Please present your blade to the judges. 394 00:13:31,519 --> 00:13:35,189 [dramatic music] 395 00:13:35,189 --> 00:13:36,649 ‐ So, Ryan, first off, 396 00:13:36,649 --> 00:13:38,067 really good choice to start over. 397 00:13:38,067 --> 00:13:39,610 And start over without the White Out 398 00:13:39,610 --> 00:13:41,571 so you didn't have to go through that process. 399 00:13:41,571 --> 00:13:43,322 ♪ ♪ 400 00:13:43,322 --> 00:13:45,241 There's a lot of mass throughout this entire blade. 401 00:13:45,241 --> 00:13:47,160 It's a lot heavier than it needs to be. 402 00:13:47,160 --> 00:13:49,412 So getting that down to maybe a quarter inch, 403 00:13:49,412 --> 00:13:51,080 it'll take a lot of that weight out. 404 00:13:51,080 --> 00:13:53,541 But, uh, steel looks solid. 405 00:13:53,541 --> 00:13:55,835 Again, good choice to start over. 406 00:13:55,835 --> 00:13:58,004 ‐ Thank you. ‐ All right, Steve, you're up. 407 00:13:58,004 --> 00:14:00,048 Please present your blade to the judges. 408 00:14:00,048 --> 00:14:02,383 [dramatic music] 409 00:14:02,383 --> 00:14:04,427 ‐ All right, Steve, nice design here. 410 00:14:04,427 --> 00:14:05,970 I like that you put a width to that 411 00:14:05,970 --> 00:14:08,347 so it feels like a good chopper and slicer. 412 00:14:08,347 --> 00:14:11,434 Um, that's not gonna penetrate so well over there. 413 00:14:11,434 --> 00:14:13,936 When we're talking about massive thrusting weapons. 414 00:14:13,936 --> 00:14:16,105 So moving forward, I hope that you 415 00:14:16,105 --> 00:14:18,524 do design something that will penetrate for the test. 416 00:14:18,524 --> 00:14:20,151 You led the way. 417 00:14:20,151 --> 00:14:21,527 Still looks solid. 418 00:14:21,527 --> 00:14:23,029 Just a lot of refinement needed. 419 00:14:23,029 --> 00:14:25,615 Good job. ‐ Thank you, sir. 420 00:14:25,615 --> 00:14:27,700 ‐ All right, Wesley, you're up. 421 00:14:27,700 --> 00:14:29,744 [dramatic music] 422 00:14:29,744 --> 00:14:31,746 ‐ Wesley, the first thing I see when I pick up this blade 423 00:14:31,746 --> 00:14:33,790 is a really interesting profile. 424 00:14:33,790 --> 00:14:36,375 You've got a nice, aggressive point here for thrusting. 425 00:14:36,375 --> 00:14:40,046 I think you chose a good time to start again. 426 00:14:40,046 --> 00:14:43,216 The one big thing is that there's a crack 427 00:14:43,216 --> 00:14:45,343 on your edge right here 428 00:14:45,343 --> 00:14:48,679 that runs about 1/8 of an inch in. 429 00:14:48,679 --> 00:14:51,557 That's a really dangerous place to have a crack. 430 00:14:51,557 --> 00:14:53,643 That needs to be addressed, because otherwise 431 00:14:53,643 --> 00:14:55,770 this thing is just gonna crack in two. 432 00:14:55,770 --> 00:14:56,813 So if you figure that out, 433 00:14:56,813 --> 00:14:57,939 I'm excited to see how this 434 00:14:57,939 --> 00:14:59,315 whole thing finishes up 435 00:14:59,315 --> 00:15:00,566 because it looks really good so far. 436 00:15:00,566 --> 00:15:01,651 ‐ Thank you, sir. 437 00:15:01,651 --> 00:15:03,277 ‐ All right, Bud, you're up. 438 00:15:03,277 --> 00:15:05,822 [dramatic music] 439 00:15:05,822 --> 00:15:08,074 ‐ Well, Bud, the thing that jumps out at me 440 00:15:08,074 --> 00:15:10,034 as soon as I pick this up is that I'm looking at 441 00:15:10,034 --> 00:15:12,912 a lot of cracks on this blade. 442 00:15:12,912 --> 00:15:14,497 If I had to pick one that scares me the most 443 00:15:14,497 --> 00:15:17,250 it's this one that comes up from here, 444 00:15:17,250 --> 00:15:19,043 and there's another one that comes down from here, 445 00:15:19,043 --> 00:15:20,336 and they're just meeting in the middle. 446 00:15:20,336 --> 00:15:22,588 You see what I'm‐‐ that here. 447 00:15:31,347 --> 00:15:35,643 ♪ ♪ 448 00:15:35,643 --> 00:15:37,436 ‐ Agree. 449 00:15:37,436 --> 00:15:39,522 ‐ All right, Bud, after evaluating your blade 450 00:15:39,522 --> 00:15:41,440 here at the table, due to the cracks, 451 00:15:41,440 --> 00:15:42,942 the judges have come to the consensus 452 00:15:42,942 --> 00:15:44,360 that your blade doesn't make the cut. 453 00:15:44,360 --> 00:15:46,571 I'd like to invite you to shake our hands, 454 00:15:46,571 --> 00:15:48,322 shake your competitors' hands, 455 00:15:48,322 --> 00:15:50,158 and then please leave The Forge. 456 00:15:50,158 --> 00:15:51,117 [dramatic music] 457 00:15:53,828 --> 00:15:55,621 ‐ I agree with the judges. 458 00:15:55,621 --> 00:16:00,126 The cracks in the blade was just too severe to fix. 459 00:16:00,126 --> 00:16:02,336 I was hoping I could weld it and grind it down, 460 00:16:02,336 --> 00:16:04,839 but I just didn't have enough time to get it done. 461 00:16:04,839 --> 00:16:07,800 I enjoyed the experience of doing it. 462 00:16:07,800 --> 00:16:10,052 I think I proved what I set out to prove. 463 00:16:10,052 --> 00:16:12,638 ♪ ♪ 464 00:16:12,638 --> 00:16:14,390 ‐ Bladesmiths, congratulations. 465 00:16:14,390 --> 00:16:16,475 You've made it to the second round of this competition, 466 00:16:16,475 --> 00:16:18,561 and now it's time to make your blades fully functional 467 00:16:18,561 --> 00:16:20,062 by attaching handles to them. 468 00:16:20,062 --> 00:16:21,814 Now in the first round of this competition, 469 00:16:21,814 --> 00:16:23,232 we had you guys make your blades 470 00:16:23,232 --> 00:16:25,902 out of scrap high carbon drill shavings. 471 00:16:25,902 --> 00:16:27,403 So it's only appropriate in this round 472 00:16:27,403 --> 00:16:29,322 that we're gonna continue with that sort of thing 473 00:16:29,322 --> 00:16:31,365 and you're gonna make your handles out of this. 474 00:16:31,365 --> 00:16:34,410 [dramatic music] 475 00:16:34,410 --> 00:16:41,417 ♪ ♪ 476 00:16:41,417 --> 00:16:44,420 Gentlemen, this is some scrap wood we found lying around. 477 00:16:44,420 --> 00:16:46,964 Some of that stuff is rotted and some of it's good to go, 478 00:16:46,964 --> 00:16:48,382 but that's part of this challenge. 479 00:16:48,382 --> 00:16:50,426 You'll have to determine which of that wood 480 00:16:50,426 --> 00:16:53,512 you wanna use to make the body of your handle. 481 00:16:53,512 --> 00:16:55,848 Additionally, you must include functional guards, 482 00:16:55,848 --> 00:16:58,267 as well as acid etches by the end of this round. 483 00:16:58,267 --> 00:17:00,228 Now we're giving you guys two whole hours 484 00:17:00,228 --> 00:17:01,687 in which to complete all that work. 485 00:17:01,687 --> 00:17:03,481 When the time runs out on this round, 486 00:17:03,481 --> 00:17:05,691 we'll be testing your blade's strength and durability 487 00:17:05,691 --> 00:17:07,526 in a trash can stab and chop 488 00:17:07,526 --> 00:17:10,404 and the edge retention in a leather bag slice. 489 00:17:10,404 --> 00:17:12,281 After your blades have been tested, 490 00:17:12,281 --> 00:17:14,325 one of your will have to surrender your blade 491 00:17:14,325 --> 00:17:15,785 and leave The Forge. 492 00:17:15,785 --> 00:17:17,954 Good luck. Your two hours starts...now. 493 00:17:17,954 --> 00:17:20,957 [intense rock music] 494 00:17:20,957 --> 00:17:23,042 ♪ ♪ 495 00:17:23,042 --> 00:17:25,294 Okay, who has the most work to do? 496 00:17:25,294 --> 00:17:27,880 ‐ Oh, boy. I would go with Wesley, man. 497 00:17:27,880 --> 00:17:29,924 He's got a lot of structural stuff 498 00:17:29,924 --> 00:17:31,217 to deal with on his blade. 499 00:17:31,217 --> 00:17:33,469 ♪ ♪ 500 00:17:33,469 --> 00:17:37,056 ‐ I have to address the crack in my blade. 501 00:17:37,056 --> 00:17:40,142 And then fit up a guard, fit up a handle, 502 00:17:40,142 --> 00:17:41,561 and sharpen the blade. 503 00:17:41,561 --> 00:17:43,062 It was like 504 00:17:43,062 --> 00:17:44,730 "Y'all trying to put three gallons of water 505 00:17:44,730 --> 00:17:45,815 into a water balloon." 506 00:17:45,815 --> 00:17:47,316 ♪ ♪ 507 00:17:47,316 --> 00:17:48,985 ‐ There's a couple spots on that spine, 508 00:17:48,985 --> 00:17:50,069 and definitely on that edge 509 00:17:50,069 --> 00:17:51,279 that he should weld up. 510 00:17:51,279 --> 00:17:53,406 ‐ The crack is all the way through. 511 00:17:53,406 --> 00:17:55,241 So I'm gonna try to re‐profile it 512 00:17:55,241 --> 00:17:56,284 and see if I can fix it. 513 00:17:56,284 --> 00:17:57,827 [saw buzzing] 514 00:17:57,827 --> 00:17:59,996 ♪ ♪ 515 00:17:59,996 --> 00:18:01,914 ‐ That scrap pile is a pile of [bleep]. 516 00:18:01,914 --> 00:18:03,583 ♪ ♪ 517 00:18:03,583 --> 00:18:05,668 I find a piece of green treated wood, 518 00:18:05,668 --> 00:18:08,170 so I know that it's good, hard wood. 519 00:18:08,170 --> 00:18:09,672 ♪ ♪ 520 00:18:09,672 --> 00:18:11,173 I've given myself an hour to grind 521 00:18:11,173 --> 00:18:13,175 all the problems that they don't like about it. 522 00:18:13,175 --> 00:18:15,428 ‐ Ryan's blade was really heavy. 523 00:18:15,428 --> 00:18:18,264 He really has to remove a lot of material. 524 00:18:18,264 --> 00:18:20,099 ‐ Get the most of that canister off 525 00:18:20,099 --> 00:18:21,475 clear down to some high carbon steel, 526 00:18:21,475 --> 00:18:22,935 so it'll hold a nice edge. 527 00:18:22,935 --> 00:18:25,187 I know I gotta get the tang down, 528 00:18:25,187 --> 00:18:26,606 'cause it's fatter than [bleep]. 529 00:18:26,606 --> 00:18:28,316 ‐ Looks like Ryan's tang actually tapered 530 00:18:28,316 --> 00:18:29,817 and got fatter. 531 00:18:29,817 --> 00:18:32,278 And for fitting a guard, how does that work? 532 00:18:32,278 --> 00:18:33,988 ‐ It doesn't. 533 00:18:33,988 --> 00:18:35,740 You have to taper it away from the point of the knife. 534 00:18:35,740 --> 00:18:37,158 And it can't go over something big 535 00:18:37,158 --> 00:18:38,659 and then get to something small. 536 00:18:38,659 --> 00:18:40,369 ‐ Fogging up! 537 00:18:40,369 --> 00:18:41,871 ♪ ♪ 538 00:18:41,871 --> 00:18:42,872 ‐ I know I've gotta get a handle 539 00:18:42,872 --> 00:18:43,914 on this thing first. 540 00:18:43,914 --> 00:18:46,584 I can do the grinding later. 541 00:18:46,584 --> 00:18:48,544 I grabbed a piece that's kind of blocky, 542 00:18:48,544 --> 00:18:49,879 but it's‐‐it's not too big. 543 00:18:49,879 --> 00:18:51,213 It's got enough meat on it. 544 00:18:51,213 --> 00:18:52,673 Looks solid from the outside, 545 00:18:52,673 --> 00:18:54,175 so I'm going with it. 546 00:18:54,175 --> 00:18:56,886 My biggest concern is getting all this put together in time. 547 00:18:56,886 --> 00:19:00,514 ‐ I think I get my blade profile small enough 548 00:19:00,514 --> 00:19:02,141 that the crack disappears. 549 00:19:02,141 --> 00:19:03,309 ♪ ♪ 550 00:19:03,309 --> 00:19:05,519 With things moving as slowly as they are, 551 00:19:05,519 --> 00:19:08,481 I take my blade and I get it in the acid etch. 552 00:19:08,481 --> 00:19:11,275 ‐ Wesley's already in the acid etch over here. 553 00:19:11,275 --> 00:19:12,985 Look at this guy. He came to play, man. 554 00:19:12,985 --> 00:19:14,320 ‐ Yeah. 555 00:19:14,320 --> 00:19:16,697 ‐ I grab what looks like 556 00:19:16,697 --> 00:19:19,700 one of the braces from a wood pallet or something. 557 00:19:19,700 --> 00:19:22,036 And that should be thick enough. 558 00:19:22,036 --> 00:19:25,414 For my guard, I decided to choose brass. 559 00:19:25,414 --> 00:19:27,500 Brass is easily drilled in machines. 560 00:19:27,500 --> 00:19:30,836 So I should be able to get it fit pretty quickly. 561 00:19:30,836 --> 00:19:32,338 ‐ One hour has elapsed. 562 00:19:32,338 --> 00:19:35,257 You have just 60 minutes remaining. 563 00:19:35,257 --> 00:19:37,426 ‐ And Ryan's made quick work of that tang. 564 00:19:37,426 --> 00:19:38,761 ‐ Yeah. 565 00:19:38,761 --> 00:19:40,096 ‐ So I got my blade where I wanted, 566 00:19:40,096 --> 00:19:41,305 got the tang down. 567 00:19:41,305 --> 00:19:42,515 Got all the meat off it. 568 00:19:42,515 --> 00:19:44,016 ♪ ♪ 569 00:19:44,016 --> 00:19:45,851 I find a piece of nice brass plate 570 00:19:45,851 --> 00:19:48,187 for my guard. 571 00:19:48,187 --> 00:19:49,522 Getting the guard to fit on the tang 572 00:19:49,522 --> 00:19:50,898 is the trickiest part, 573 00:19:50,898 --> 00:19:52,400 'cause you don't have a square drill bit. 574 00:19:52,400 --> 00:19:53,609 You've gotta drill round, 575 00:19:53,609 --> 00:19:54,860 and then flatten it back out. 576 00:19:54,860 --> 00:19:57,530 I love it, love it, love it. 577 00:19:57,530 --> 00:19:59,198 ♪ ♪ 578 00:19:59,198 --> 00:20:02,284 ‐ I'm going for a through tang construction on this knife. 579 00:20:02,284 --> 00:20:04,412 So I choose to heat up this tang 580 00:20:04,412 --> 00:20:05,454 and peen it over. 581 00:20:05,454 --> 00:20:06,956 ♪ ♪ 582 00:20:06,956 --> 00:20:08,290 ‐ Looks like Steve might be setting up 583 00:20:08,290 --> 00:20:09,959 to peen his tang over. 584 00:20:09,959 --> 00:20:12,420 As long as only a little bit of that 585 00:20:12,420 --> 00:20:14,463 peen part is sticking out, 586 00:20:14,463 --> 00:20:16,215 it's‐‐it's not a bad way to do it. 587 00:20:16,215 --> 00:20:19,218 ‐ I don't wanna heat up that epoxy if I can help it. 588 00:20:19,218 --> 00:20:21,262 I've got some epoxy in that handle 589 00:20:21,262 --> 00:20:22,430 to try to set things up. 590 00:20:22,430 --> 00:20:23,556 It's gotta work. 591 00:20:23,556 --> 00:20:24,974 I really don't have a chance 592 00:20:24,974 --> 00:20:26,100 to take it back apart and redo it. 593 00:20:26,100 --> 00:20:28,060 [hammer pounding] 594 00:20:28,060 --> 00:20:31,731 ‐ He should not be hitting that hard to peen a tang. 595 00:20:31,731 --> 00:20:33,816 ‐ I may have been a little long there. 596 00:20:33,816 --> 00:20:35,234 Yes, I was. 597 00:20:37,319 --> 00:20:39,697 ‐ He did i‐ He did it. He did it. He did it. 598 00:20:39,697 --> 00:20:42,408 ‐ And it breaks off. Now what? 599 00:20:42,408 --> 00:20:45,077 ‐ He had about 1/8 of an inch by about 3/4 600 00:20:45,077 --> 00:20:46,370 sticking up out of there. 601 00:20:46,370 --> 00:20:47,580 And just some blind old hitting. 602 00:20:47,580 --> 00:20:49,749 ♪ ♪ 603 00:20:49,749 --> 00:20:52,251 ‐ I think we're good. I got a little sigh of relief. 604 00:20:52,251 --> 00:20:53,836 Got enough left to peen it over. 605 00:20:53,836 --> 00:20:55,379 I just hope it holds. 606 00:20:55,379 --> 00:20:57,423 We ain't gonna turn in an unfinished blade. 607 00:20:57,423 --> 00:20:59,383 ‐ 15 minutes, bladesmiths. 608 00:20:59,383 --> 00:21:00,801 ♪ ♪ 609 00:21:00,801 --> 00:21:03,053 ‐ At this point, everything's fitting nice and tight. 610 00:21:03,053 --> 00:21:04,263 ♪ ♪ 611 00:21:04,263 --> 00:21:06,098 I just need to get some epoxy in it 612 00:21:06,098 --> 00:21:07,600 and get my handle ground down 613 00:21:07,600 --> 00:21:08,934 so it'll be nice and comfortable. 614 00:21:08,934 --> 00:21:09,935 [machine whirring] 615 00:21:09,935 --> 00:21:11,270 ♪ ♪ 616 00:21:11,270 --> 00:21:15,024 ‐ I have yet to sharpen my blade. 617 00:21:15,024 --> 00:21:18,694 ‐ All right, so Wesley's got everything all glued up. 618 00:21:18,694 --> 00:21:20,237 ‐ While the glue is hardening, 619 00:21:20,237 --> 00:21:22,615 I start working on shaving the handle. 620 00:21:22,615 --> 00:21:24,450 ‐ Five minutes! 621 00:21:24,450 --> 00:21:26,786 ♪ ♪ 622 00:21:26,786 --> 00:21:28,621 ‐ Steve's still working on those bevels, man. 623 00:21:28,621 --> 00:21:29,997 ‐ Yeah. 624 00:21:29,997 --> 00:21:31,248 ‐ I just hope Steve doesn't forget 625 00:21:31,248 --> 00:21:32,541 to acid etch his blade. 626 00:21:32,541 --> 00:21:34,293 [whirring stops] 627 00:21:34,293 --> 00:21:36,462 ‐ Just got a few seconds left, and I go to the etch. 628 00:21:36,462 --> 00:21:37,797 The cap is stuck on it. 629 00:21:37,797 --> 00:21:38,798 ♪ ♪ 630 00:21:38,798 --> 00:21:40,633 Why won't it come off? 631 00:21:40,633 --> 00:21:42,968 ‐ Steve, wrestling with the lid of the acid. 632 00:21:42,968 --> 00:21:44,970 [all chuckling] 633 00:21:44,970 --> 00:21:46,514 ‐ Just in time. 634 00:21:46,514 --> 00:21:49,308 ‐ Five, four, three, 635 00:21:49,308 --> 00:21:51,560 two, one! 636 00:21:51,560 --> 00:21:53,062 Bladesmiths, stop what you're doing. 637 00:21:53,062 --> 00:21:54,897 Throw your hands in the air. ‐ Yeah, buddy. 638 00:21:54,897 --> 00:21:57,316 ‐ The second round of competition is over. 639 00:21:57,316 --> 00:21:58,651 ‐ Whoo! [clapping] 640 00:21:58,651 --> 00:22:01,320 ‐ Way to go, guys. 641 00:22:01,320 --> 00:22:03,322 ‐ Way to go. ‐ [grunts] 642 00:22:03,322 --> 00:22:04,824 I am so pumped up. 643 00:22:04,824 --> 00:22:07,368 This challenge was awesome. It was exciting. 644 00:22:07,368 --> 00:22:09,119 And I think I've got a good blade. 645 00:22:09,119 --> 00:22:10,663 ♪ ♪ 646 00:22:10,663 --> 00:22:12,331 ‐ Bladesmiths, welcome to the strength test. 647 00:22:12,331 --> 00:22:14,500 The trash can stab and chop. 648 00:22:14,500 --> 00:22:15,835 ♪ ♪ 649 00:22:15,835 --> 00:22:17,419 To test the tip of your blades, 650 00:22:17,419 --> 00:22:18,629 I'll be stabbing them into these trash cans. 651 00:22:18,629 --> 00:22:20,256 And to test everything else, 652 00:22:20,256 --> 00:22:22,258 I'll be chopping mercilessly into them as well. 653 00:22:22,258 --> 00:22:23,676 Remember, this test is all about 654 00:22:23,676 --> 00:22:25,177 what the cans do to your blades, 655 00:22:25,177 --> 00:22:26,929 and not what the blades do to the cans. 656 00:22:26,929 --> 00:22:28,681 Ryan, you're up first. You ready? 657 00:22:28,681 --> 00:22:31,183 ‐ Tear it up. ‐ All right. 658 00:22:31,183 --> 00:22:33,394 [dramatic music] 659 00:22:33,394 --> 00:22:35,187 ‐ Stabbing into a trash can 660 00:22:35,187 --> 00:22:37,773 and then chopping the trash can up 661 00:22:37,773 --> 00:22:39,275 is giving me a little worry, 662 00:22:39,275 --> 00:22:42,027 but I believe that my blade is strong. 663 00:22:42,027 --> 00:22:46,448 ♪ ♪ 664 00:22:46,448 --> 00:22:49,493 [upbeat rock music] 665 00:22:49,493 --> 00:22:56,458 ♪ ♪ 666 00:23:06,010 --> 00:23:07,887 ‐ Well, Ryan, you're all in one piece. 667 00:23:07,887 --> 00:23:09,346 That's a good thing. 668 00:23:09,346 --> 00:23:11,348 Looking at your edge here, 669 00:23:11,348 --> 00:23:13,767 there's a lot of serrations going on. 670 00:23:13,767 --> 00:23:16,395 I can get my fingernail underneath it. 671 00:23:16,395 --> 00:23:18,147 It's‐‐it's rolled over pretty severely. 672 00:23:18,147 --> 00:23:21,108 Your tip held up great. 673 00:23:21,108 --> 00:23:22,359 Your handle‐‐ 674 00:23:22,359 --> 00:23:25,404 it's square but rounded a lot too. 675 00:23:25,404 --> 00:23:27,406 So it was rotating in my hand. 676 00:23:27,406 --> 00:23:29,241 I had to readjust to get it back. 677 00:23:29,241 --> 00:23:30,993 But, uh, you took a bunch of scraps 678 00:23:30,993 --> 00:23:33,746 and you made a knife that holds up against a trash can. 679 00:23:33,746 --> 00:23:35,414 So well done for that. 680 00:23:35,414 --> 00:23:36,916 All right, Steve. You see what we're up to. 681 00:23:36,916 --> 00:23:38,250 How are you feeling? ‐ I feel good. 682 00:23:38,250 --> 00:23:39,752 ‐ All right. Let's do this. 683 00:23:39,752 --> 00:23:41,503 [dramatic music] 684 00:23:41,503 --> 00:23:44,423 ‐ This is a Damascus blade made out of trash. 685 00:23:44,423 --> 00:23:46,008 This thing could blow apart 686 00:23:46,008 --> 00:23:48,260 like a grenade when they hit this can. 687 00:23:48,260 --> 00:23:49,845 Butterflies in my stomach. 688 00:23:49,845 --> 00:23:52,890 [upbeat rock music] 689 00:23:52,890 --> 00:23:59,855 ♪ ♪ 690 00:24:04,109 --> 00:24:06,111 [clears throat] 691 00:24:06,111 --> 00:24:07,988 ‐ Well, Steve, this is a heavy blade. 692 00:24:07,988 --> 00:24:09,698 It's all still in one piece. 693 00:24:09,698 --> 00:24:12,493 There is, however, some rolling right here. 694 00:24:12,493 --> 00:24:13,786 One significant roll. 695 00:24:13,786 --> 00:24:15,287 As for the tip, 696 00:24:15,287 --> 00:24:17,706 there's some dulling that happened 697 00:24:17,706 --> 00:24:19,291 from going into the can. 698 00:24:19,291 --> 00:24:21,961 The handle‐‐you left some flats on here 699 00:24:21,961 --> 00:24:23,170 which is really comfortable. 700 00:24:23,170 --> 00:24:24,713 It kept me in place. 701 00:24:24,713 --> 00:24:27,967 All in all, well done. ‐ Thank you, sir. 702 00:24:27,967 --> 00:24:29,301 ‐ Wesley, you're up. How you feel? 703 00:24:29,301 --> 00:24:30,886 ‐ Ain't a word for it. [both laugh] 704 00:24:30,886 --> 00:24:32,096 ‐ All right. 705 00:24:32,096 --> 00:24:33,722 ♪ ♪ 706 00:24:33,722 --> 00:24:35,975 ‐ If we're doing a range of one to ten, 707 00:24:35,975 --> 00:24:38,477 my confidence is probably 6 3/4. 708 00:24:41,230 --> 00:24:44,566 I'm w ‐ I'm worried thatill be there will be a crack, 709 00:24:44,566 --> 00:24:46,318 and that blade snaps in half. 710 00:24:46,318 --> 00:24:49,363 [dramatic music] 711 00:24:49,363 --> 00:24:56,328 ♪ ♪ 712 00:25:01,917 --> 00:25:03,043 [exhales] 713 00:25:03,043 --> 00:25:05,170 ♪ ♪ 714 00:25:05,170 --> 00:25:07,548 ‐ Wow, from all of that chopping, 715 00:25:07,548 --> 00:25:11,176 there's a little tiny nick right here 716 00:25:11,176 --> 00:25:13,053 and there's some dulling up towards the tip. 717 00:25:13,053 --> 00:25:15,222 Just less sharp here than it was before. 718 00:25:15,222 --> 00:25:18,017 Moving back to your handle, I like this palm swell idea. 719 00:25:18,017 --> 00:25:19,560 It really holds me in there nicely. 720 00:25:19,560 --> 00:25:20,602 There's a lot of guard here. 721 00:25:20,602 --> 00:25:22,062 You know, you could take away 722 00:25:22,062 --> 00:25:23,689 almost 3/4 of an inch of that. 723 00:25:23,689 --> 00:25:25,065 It'd still be a functional guard. 724 00:25:25,065 --> 00:25:27,818 But for a junkyard piece of pine, 725 00:25:27,818 --> 00:25:30,029 it held up really well. ‐ Thank you, sir. 726 00:25:30,029 --> 00:25:31,030 ♪ ♪ 727 00:25:31,030 --> 00:25:32,406 ‐ All right, bladesmiths. 728 00:25:32,406 --> 00:25:33,365 We're done with the trash‐talking. 729 00:25:33,365 --> 00:25:34,825 Now it's time to find out 730 00:25:34,825 --> 00:25:36,535 how sharp your blades are. 731 00:25:36,535 --> 00:25:39,038 This is the sharpness test‐‐ the leather bag slice. 732 00:25:39,038 --> 00:25:40,164 ♪ ♪ 733 00:25:40,164 --> 00:25:41,248 To test the sharpness 734 00:25:41,248 --> 00:25:42,708 of the edge of your blade, 735 00:25:42,708 --> 00:25:43,876 I'm gonna take your weapon and slash across 736 00:25:43,876 --> 00:25:45,252 these thick leather bags. 737 00:25:45,252 --> 00:25:46,962 Now unlike the strength test, 738 00:25:46,962 --> 00:25:49,381 this is all about what your blade's edge 739 00:25:49,381 --> 00:25:51,175 does to these leather bags. 740 00:25:51,175 --> 00:25:52,843 Ryan, you're up first. You ready for this? 741 00:25:52,843 --> 00:25:54,762 ‐ Let's rock. ‐ All right, let's do it. 742 00:25:54,762 --> 00:25:59,516 ♪ ♪ 743 00:25:59,516 --> 00:26:02,561 [upbeat rock music] 744 00:26:02,561 --> 00:26:07,900 ♪ ♪ 745 00:26:07,900 --> 00:26:09,359 All right, Ryan, 746 00:26:09,359 --> 00:26:10,444 let's talk about your blade here. 747 00:26:10,444 --> 00:26:12,029 First up, your handle. 748 00:26:12,029 --> 00:26:14,907 It's comfortable. I can get a good grip in here. 749 00:26:14,907 --> 00:26:16,950 It's ovoid, I can tell where the edge is. 750 00:26:16,950 --> 00:26:18,577 On the first two strikes right there you can see 751 00:26:18,577 --> 00:26:20,454 you got nice, clean cuts. 752 00:26:20,454 --> 00:26:22,790 On the third one, must have hit a dull spot right there, 753 00:26:22,790 --> 00:26:24,208 'cause it didn't cut all the way through. 754 00:26:24,208 --> 00:26:26,627 But with two cuts like that? It will cut. 755 00:26:26,627 --> 00:26:28,087 ‐ Thank you. 756 00:26:28,087 --> 00:26:29,296 ‐ All right, Steve, it's your turn. 757 00:26:29,296 --> 00:26:30,255 You ready, sir? ‐ I'm ready. 758 00:26:30,255 --> 00:26:31,423 ‐ Let's do this. 759 00:26:31,423 --> 00:26:33,133 ‐ We have some edge damage 760 00:26:33,133 --> 00:26:35,135 after chopping into the steel can. 761 00:26:35,135 --> 00:26:37,179 I feel like I'm a little bit behind here, 762 00:26:37,179 --> 00:26:39,264 and I'm just praying this thing cuts. 763 00:26:39,264 --> 00:26:42,267 [dramatic music] 764 00:26:42,267 --> 00:26:47,397 ♪ ♪ 765 00:26:47,397 --> 00:26:48,482 [whispering] There we go. 766 00:26:48,482 --> 00:26:52,778 ♪ ♪ 767 00:26:52,778 --> 00:26:55,239 ‐ All right, Steve, let's talk about your blade here. 768 00:26:55,239 --> 00:26:56,990 First up, your handle construction. 769 00:26:56,990 --> 00:26:58,283 I like the design that you have here 770 00:26:58,283 --> 00:26:59,660 where the belly just drops into there 771 00:26:59,660 --> 00:27:01,120 like a finger weld. 772 00:27:01,120 --> 00:27:03,372 And allows my hand to feel comfortable. 773 00:27:03,372 --> 00:27:04,581 The blade is heavy. 774 00:27:04,581 --> 00:27:06,291 On the first two strikes, 775 00:27:06,291 --> 00:27:07,626 it didn't cut all the way through. 776 00:27:07,626 --> 00:27:09,294 But on the third one, once you find a sweet spot, 777 00:27:09,294 --> 00:27:12,297 then you adjust to that, it does give a very deep cut. 778 00:27:12,297 --> 00:27:15,217 Overall, sir, it will cut. ‐ Thank you, sir. 779 00:27:15,217 --> 00:27:16,260 ‐ All right, Wesley, your turn. 780 00:27:16,260 --> 00:27:17,678 So you ready? 781 00:27:17,678 --> 00:27:18,804 ‐ Stay ready, ain't gotta get ready. 782 00:27:18,804 --> 00:27:19,805 ‐ All right, let's do it. 783 00:27:19,805 --> 00:27:21,014 ♪ ♪ 784 00:27:21,014 --> 00:27:22,808 ‐ My heart's racing. 785 00:27:22,808 --> 00:27:26,478 I didn't have too much time to sharpen my blade. 786 00:27:26,478 --> 00:27:28,689 I don't know if it has enough weight 787 00:27:28,689 --> 00:27:31,149 to compensate for a dull blade. 788 00:27:31,149 --> 00:27:34,194 [dramatic music] 789 00:27:34,194 --> 00:27:41,159 ♪ ♪ 790 00:27:48,166 --> 00:27:50,878 ‐ All right, Wesley, let's talk about your blade here. 791 00:27:50,878 --> 00:27:52,629 Your handle‐‐it's comfortable. 792 00:27:52,629 --> 00:27:54,506 I like that you put the weld right there, 793 00:27:54,506 --> 00:27:56,466 so I can get my good grip. 794 00:27:56,466 --> 00:27:58,176 Now your edge. 795 00:27:58,176 --> 00:28:00,012 You have a light, fast blade here. 796 00:28:00,012 --> 00:28:01,847 It is sharp in here, but the design 797 00:28:01,847 --> 00:28:03,891 for this particular leather bag‐‐ 798 00:28:03,891 --> 00:28:06,560 unfortunately, it will not cut. 799 00:28:06,560 --> 00:28:09,521 ♪ ♪ 800 00:28:09,521 --> 00:28:10,856 ‐ All right, bladesmiths. 801 00:28:10,856 --> 00:28:12,149 The judges have evaluated 802 00:28:12,149 --> 00:28:13,692 the performances of your blades, 803 00:28:13,692 --> 00:28:15,861 and the bladesmith leaving The Forge is... 804 00:28:15,861 --> 00:28:18,697 ♪ ♪ 805 00:28:18,697 --> 00:28:19,823 Wesley. 806 00:28:19,823 --> 00:28:21,241 Your blade didn't make the cut. 807 00:28:21,241 --> 00:28:23,076 Doug Marcaida's gonna tell you why. 808 00:28:23,076 --> 00:28:24,453 ‐ Wesley, first of all, I commend you 809 00:28:24,453 --> 00:28:26,538 for being a great competitor. 810 00:28:26,538 --> 00:28:28,749 You fought all the way through, even when you had to restart. 811 00:28:28,749 --> 00:28:30,000 And you handed us a beautiful design blade 812 00:28:30,000 --> 00:28:31,668 and a comfortable one. 813 00:28:31,668 --> 00:28:33,712 But in the strength test, it took some dulling. 814 00:28:33,712 --> 00:28:35,339 And because of that, it did not perform well 815 00:28:35,339 --> 00:28:36,673 in the sharpness test. 816 00:28:36,673 --> 00:28:38,967 For that reason, we're letting you go. 817 00:28:38,967 --> 00:28:41,053 ‐ Wesley, please surrender your blade. 818 00:28:41,053 --> 00:28:43,597 [dramatic music] 819 00:28:43,597 --> 00:28:45,349 ‐ I'm happy 'cause I made it way farther 820 00:28:45,349 --> 00:28:46,391 than I thought I was gonna make it. 821 00:28:46,391 --> 00:28:48,352 But I would've liked to 822 00:28:48,352 --> 00:28:50,103 keep pushing and keep fighting and make it 823 00:28:50,103 --> 00:28:51,980 to be Forged in Fire champion. 824 00:28:51,980 --> 00:28:53,941 But I'm proud of what I did. 825 00:28:53,941 --> 00:28:57,277 I have never even attempted anything like this before. 826 00:28:57,277 --> 00:28:58,445 ♪ ♪ 827 00:28:58,445 --> 00:28:59,655 First thing I'm gonna do? 828 00:28:59,655 --> 00:29:01,073 Just get back to learning, 829 00:29:01,073 --> 00:29:02,532 get back to evolving, 830 00:29:02,532 --> 00:29:03,617 and just try to make myself better. 831 00:29:03,617 --> 00:29:05,953 ♪ ♪ 832 00:29:05,953 --> 00:29:08,121 ‐ Ryan, Steve, congratulations. 833 00:29:08,121 --> 00:29:10,123 You guys have earned your spot 834 00:29:10,123 --> 00:29:12,084 in the final round of this competition. 835 00:29:12,084 --> 00:29:13,293 You came here, 836 00:29:13,293 --> 00:29:15,045 you made beautiful blades out of scraps, 837 00:29:15,045 --> 00:29:16,880 and now it's time to send you back to your home forges 838 00:29:16,880 --> 00:29:19,758 to recreate this iconic weapon from history. 839 00:29:19,758 --> 00:29:23,136 [dramatic music] 840 00:29:23,136 --> 00:29:24,763 The nimcha. 841 00:29:24,763 --> 00:29:26,306 To tell you more about it, 842 00:29:26,306 --> 00:29:27,724 historic weapons recreation specialist 843 00:29:27,724 --> 00:29:29,267 David Baker. 844 00:29:29,267 --> 00:29:31,311 ‐ The nimcha is a single‐handed scimitar 845 00:29:31,311 --> 00:29:33,814 widely used throughout North Africa. 846 00:29:33,814 --> 00:29:36,024 This unique weapon featured a hook handle, 847 00:29:36,024 --> 00:29:38,110 knuckle guard, and forward pointing quillions 848 00:29:38,110 --> 00:29:39,820 that were designed as a defensive tool 849 00:29:39,820 --> 00:29:41,947 to catch an opponent's blade. 850 00:29:41,947 --> 00:29:43,949 Featuring a deep fuller on both sides, 851 00:29:43,949 --> 00:29:46,660 the sword was light, quick, and deadly on the battlefield. 852 00:29:46,660 --> 00:29:48,662 Largely made of recycled blades, 853 00:29:48,662 --> 00:29:50,288 the nimcha could be forged quickly 854 00:29:50,288 --> 00:29:51,456 and in large quantities, 855 00:29:51,456 --> 00:29:52,666 and was a crucial weapon 856 00:29:52,666 --> 00:29:54,334 used by the Ottoman soldiers 857 00:29:54,334 --> 00:29:57,629 during the Great Siege of Malta in 1565. 858 00:29:57,629 --> 00:30:00,048 ‐ Bladesmiths, in the final round on this competition, 859 00:30:00,048 --> 00:30:03,010 we want you to forge your version of this nimcha. 860 00:30:03,010 --> 00:30:05,012 It must fall within the following parameters. 861 00:30:05,012 --> 00:30:08,515 The length of the blade must fall between 27 and 29 inches. 862 00:30:08,515 --> 00:30:11,184 The blade must be curved and sharpened on one edge. 863 00:30:11,184 --> 00:30:13,186 It must have three upswept quillions, 864 00:30:13,186 --> 00:30:16,023 a knuckle‐bow, and a boot or hook‐shaped pommel. 865 00:30:16,023 --> 00:30:17,899 At the end of your four days, you'll return 866 00:30:17,899 --> 00:30:20,193 and present your nimchas to our judges. 867 00:30:20,193 --> 00:30:21,737 And after they've tested them, 868 00:30:21,737 --> 00:30:23,864 and evaluated your craftsmanship, 869 00:30:23,864 --> 00:30:25,991 they'll declare one of you the Forged in Fire champion 870 00:30:25,991 --> 00:30:28,160 who leaves here with a check for $10,000. 871 00:30:28,160 --> 00:30:30,162 Pay attention to the details, bladesmiths. 872 00:30:30,162 --> 00:30:32,205 We'll see you in four days. 873 00:30:32,205 --> 00:30:33,707 ‐ Good luck. ‐ Good luck. 874 00:30:33,707 --> 00:30:36,543 [upbeat rock music] 875 00:30:36,543 --> 00:30:38,962 ‐ We're in Omaha, Illinois. It's raining outside. 876 00:30:38,962 --> 00:30:40,547 It's a good day to work in the shop, 877 00:30:40,547 --> 00:30:41,590 building our nimcha. 878 00:30:41,590 --> 00:30:43,175 I'm gonna put the fullers in 879 00:30:43,175 --> 00:30:44,342 before I start forging. 880 00:30:44,342 --> 00:30:46,011 [saw grinding] 881 00:30:46,011 --> 00:30:50,390 ♪ ♪ 882 00:30:50,390 --> 00:30:51,975 My point's going good. 883 00:30:51,975 --> 00:30:54,019 Got it pretty close to what I want. 884 00:30:54,019 --> 00:30:55,979 My forge is not real long. 885 00:30:55,979 --> 00:30:58,398 And while I'm forging this blade, it wants to warp. 886 00:30:58,398 --> 00:31:00,692 I don't think I accounted for the‐‐ 887 00:31:00,692 --> 00:31:02,778 the length of this blade and the weight. 888 00:31:02,778 --> 00:31:04,071 The ends wanna hang out. 889 00:31:04,071 --> 00:31:05,697 I've got a lot of steel there. 890 00:31:05,697 --> 00:31:07,157 Lot of stuff to manage. 891 00:31:07,157 --> 00:31:08,283 That's gonna be the challenge. 892 00:31:08,283 --> 00:31:10,077 To keep that under control. 893 00:31:10,077 --> 00:31:12,537 I've got my blade shaped out pretty close to parameters 894 00:31:12,537 --> 00:31:14,915 so day one in the books. 895 00:31:14,915 --> 00:31:17,542 [upbeat rock music] 896 00:31:17,542 --> 00:31:19,211 ‐ Back at the home forge, 897 00:31:19,211 --> 00:31:20,962 ready to start beating out this nimcha. 898 00:31:20,962 --> 00:31:22,964 I've never made anything this big. 899 00:31:22,964 --> 00:31:25,467 I'm used to making 3 to 5‐inch skinners. 900 00:31:25,467 --> 00:31:28,095 So it's gonna be a difficult build to keep it straight. 901 00:31:28,095 --> 00:31:29,429 ♪ ♪ 902 00:31:29,429 --> 00:31:32,182 I've chosen a piece of 5160 spring steel. 903 00:31:32,182 --> 00:31:34,810 I'm very familiar with it and it holds a good edge. 904 00:31:34,810 --> 00:31:36,478 As I'm beveling this thing, 905 00:31:36,478 --> 00:31:38,271 the natural curve is coming into this metal 906 00:31:38,271 --> 00:31:39,773 and making a curve for me. 907 00:31:39,773 --> 00:31:42,526 It flowed in and it just worked out. 908 00:31:42,526 --> 00:31:44,945 I feel good at the end of day one. 909 00:31:44,945 --> 00:31:46,738 And my blade is forged out. 910 00:31:46,738 --> 00:31:48,615 Parameters are met on it. 911 00:31:48,615 --> 00:31:52,285 Tomorrow, I just gotta go in and go full throttle. 912 00:31:52,285 --> 00:31:53,829 ‐ It's the beginning of day two, 913 00:31:53,829 --> 00:31:55,288 so we're gonna get after it. 914 00:31:55,288 --> 00:31:56,623 ♪ ♪ 915 00:31:56,623 --> 00:31:58,458 Working on my guard right now. 916 00:31:58,458 --> 00:32:01,670 I'm trying to get a guard shaped out of a railroad spike. 917 00:32:01,670 --> 00:32:03,463 And I'm using this old hammer. 918 00:32:03,463 --> 00:32:05,257 It needs some maintenance, but still, 919 00:32:05,257 --> 00:32:07,425 we're just gonna make it work the best we can. 920 00:32:07,425 --> 00:32:09,219 ♪ ♪ 921 00:32:12,305 --> 00:32:15,058 ‐ I think this‐‐think this belt's hitting this flywheel. 922 00:32:15,058 --> 00:32:17,269 Knocking it off. 923 00:32:17,269 --> 00:32:18,728 This has got me kind of behind. 924 00:32:18,728 --> 00:32:20,105 The hammer just wasn't 925 00:32:20,105 --> 00:32:22,023 performing like it should. 926 00:32:22,023 --> 00:32:23,233 Aw, see. 927 00:32:23,233 --> 00:32:25,277 That's what that is, duct tape. 928 00:32:25,277 --> 00:32:26,945 Throw some more tape on that. 929 00:32:26,945 --> 00:32:29,447 ♪ ♪ 930 00:32:29,447 --> 00:32:30,782 Let's see. 931 00:32:30,782 --> 00:32:32,784 ♪ ♪ 932 00:32:32,784 --> 00:32:35,287 That seemed to work a lot better. 933 00:32:35,287 --> 00:32:36,997 End of day two. I feel pretty good. 934 00:32:36,997 --> 00:32:39,749 Got my guard done today. Got it fit up. 935 00:32:39,749 --> 00:32:41,626 I'm pretty happy with how it turned out. 936 00:32:41,626 --> 00:32:42,794 ♪ ♪ 937 00:32:42,794 --> 00:32:44,045 ‐ I'm pretty excited where 938 00:32:44,045 --> 00:32:45,130 I finished up yesterday. 939 00:32:45,130 --> 00:32:46,631 I got all the forging done. 940 00:32:46,631 --> 00:32:48,592 Today, I'm going to finish grinding 941 00:32:48,592 --> 00:32:49,926 and put fullers in it, 942 00:32:49,926 --> 00:32:52,179 and get it ready for quenching. 943 00:32:52,179 --> 00:32:54,139 I'm gonna take a lot of the mass out, 944 00:32:54,139 --> 00:32:55,974 but I will leave some meat on the bones 945 00:32:55,974 --> 00:32:57,893 so it doesn't warp or twist on me. 946 00:32:57,893 --> 00:32:59,644 ♪ ♪ 947 00:32:59,644 --> 00:33:02,397 Everything's going smooth, just like it's supposed to. 948 00:33:02,397 --> 00:33:05,150 Now that the bevels are in, I'm ready to go in to quench. 949 00:33:05,150 --> 00:33:06,651 I'm a little nervous about the quench, 950 00:33:06,651 --> 00:33:08,236 being a long blade like it is. 951 00:33:08,236 --> 00:33:09,654 There's a lot of things that can go wrong. 952 00:33:09,654 --> 00:33:14,826 ♪ ♪ 953 00:33:14,826 --> 00:33:17,495 I didn't hear no tings or pings. 954 00:33:17,495 --> 00:33:19,331 I feel pretty good about it, but we'll have to look and see 955 00:33:19,331 --> 00:33:20,582 after it cools off. 956 00:33:20,582 --> 00:33:21,708 ♪ ♪ 957 00:33:21,708 --> 00:33:23,752 And we've got a straight blade. 958 00:33:23,752 --> 00:33:25,086 ♪ ♪ 959 00:33:25,086 --> 00:33:26,296 Perfect. 960 00:33:26,296 --> 00:33:28,048 End of day two. I feel great. 961 00:33:28,048 --> 00:33:30,383 I got the blade quenched. I got the fullers put in it. 962 00:33:30,383 --> 00:33:32,886 It's turning out to be a beautiful blade. 963 00:33:32,886 --> 00:33:35,013 ‐ Day three. I feel good. 964 00:33:35,013 --> 00:33:37,682 Right now, it's heat treat time. 965 00:33:37,682 --> 00:33:39,517 It's a little nerve‐wracking. 966 00:33:39,517 --> 00:33:41,353 You put all this work into something, 967 00:33:41,353 --> 00:33:43,772 and it all hinges on this one moment. 968 00:33:43,772 --> 00:33:48,985 ♪ ♪ 969 00:33:48,985 --> 00:33:51,154 This is where things can go bad. 970 00:33:52,948 --> 00:33:53,949 [bleep] 971 00:33:53,949 --> 00:33:55,575 ♪ ♪ 972 00:33:55,575 --> 00:33:57,535 Uh‐oh. 973 00:33:57,535 --> 00:34:00,247 Cover it up with something. 974 00:34:00,247 --> 00:34:02,707 Outside of the fireball in my face, 975 00:34:02,707 --> 00:34:03,959 the heat treat went well. 976 00:34:03,959 --> 00:34:06,002 I had some minor bends, 977 00:34:06,002 --> 00:34:08,380 and I think I can clean it up good on the grinder. 978 00:34:08,380 --> 00:34:10,590 We're ready to start on the handle tomorrow. 979 00:34:10,590 --> 00:34:12,550 ‐ Today is day four, 980 00:34:12,550 --> 00:34:14,678 and also it's my birthday. 981 00:34:14,678 --> 00:34:17,013 I've gotta finish cleaning the guard up on it. 982 00:34:17,013 --> 00:34:18,390 Fit it. Put a pommel on it. 983 00:34:18,390 --> 00:34:19,891 ♪ ♪ 984 00:34:19,891 --> 00:34:21,643 My brain's running 100 miles an hour, 985 00:34:21,643 --> 00:34:24,104 and I can't figure out how to get this pommel to stay. 986 00:34:24,104 --> 00:34:26,481 After I sat back, I figured out how to do it. 987 00:34:26,481 --> 00:34:29,234 I thread my tang and screwed my pommel on. 988 00:34:29,234 --> 00:34:30,860 It's gonna give enough weight on the back side, I think, 989 00:34:30,860 --> 00:34:32,696 to balance this blade out. 990 00:34:32,696 --> 00:34:34,322 Now that everything's glued together, 991 00:34:34,322 --> 00:34:36,408 and everything's all constructed, 992 00:34:36,408 --> 00:34:39,411 I go to finish sharpening and polishing my blade. 993 00:34:39,411 --> 00:34:41,204 ♪ ♪ 994 00:34:41,204 --> 00:34:43,415 Now ready to test it and see what it's gonna do. 995 00:34:43,415 --> 00:34:45,750 ♪ ♪ 996 00:34:45,750 --> 00:34:47,585 End of day four and I feel great. 997 00:34:47,585 --> 00:34:50,380 The blade's done and I get a surprise birthday party 998 00:34:50,380 --> 00:34:51,423 from my family. 999 00:34:51,423 --> 00:34:52,632 It makes me really happy. 1000 00:34:52,632 --> 00:34:54,259 Just couldn't be a better day. 1001 00:34:54,259 --> 00:34:55,760 I'm ready for competition. 1002 00:34:55,760 --> 00:34:58,054 ♪ ♪ 1003 00:34:58,054 --> 00:35:01,016 [dramatic music] 1004 00:35:01,016 --> 00:35:04,311 ♪ ♪ 1005 00:35:04,311 --> 00:35:06,438 ‐ Ryan, Steve, welcome back to The Forge. 1006 00:35:06,438 --> 00:35:09,149 You bladesmiths have had four days at your home forge 1007 00:35:09,149 --> 00:35:10,609 to work on your nimchas. 1008 00:35:10,609 --> 00:35:12,110 Ryan, how did it go? 1009 00:35:12,110 --> 00:35:13,612 ‐ Went great. Had a fun time building. 1010 00:35:13,612 --> 00:35:15,113 ♪ ♪ 1011 00:35:15,113 --> 00:35:17,532 Made out of 5160 spring steel, 1012 00:35:17,532 --> 00:35:20,910 mild steel guard with a hard maple handle. 1013 00:35:20,910 --> 00:35:23,455 Stainless steel butt cap with a stainless steel wing nut. 1014 00:35:23,455 --> 00:35:24,497 ♪ ♪ 1015 00:35:24,497 --> 00:35:25,832 ‐ Looks pretty cool, man. ‐ Thank you. 1016 00:35:25,832 --> 00:35:27,417 ‐ All right, Steve, how'd it go for you? 1017 00:35:27,417 --> 00:35:29,628 ‐ I had a couple hiccups, but we got through them. 1018 00:35:29,628 --> 00:35:31,546 ♪ ♪ 1019 00:35:31,546 --> 00:35:34,174 I've got an 80CRV2 blade 1020 00:35:34,174 --> 00:35:35,967 with a micarta handle, 1021 00:35:35,967 --> 00:35:38,470 brass and imitation ivory spacer, 1022 00:35:38,470 --> 00:35:41,097 and I made my guard out of a railroad spike. 1023 00:35:41,097 --> 00:35:43,808 ‐ Well, both of these blades look really nice. 1024 00:35:43,808 --> 00:35:45,977 However, this is all about performance 1025 00:35:45,977 --> 00:35:48,605 as we put your blades through our three weapons test. 1026 00:35:48,605 --> 00:35:50,482 There'll be a strength test, a sharpness test, 1027 00:35:50,482 --> 00:35:52,859 and up first, of course, the KEAL test. 1028 00:35:52,859 --> 00:35:53,860 Doug? 1029 00:35:55,987 --> 00:35:58,156 ‐ Bladesmiths, welcome to the KEAL test. 1030 00:35:58,156 --> 00:35:59,157 ♪ ♪ 1031 00:35:59,157 --> 00:36:00,116 It's time to find out 1032 00:36:00,116 --> 00:36:01,159 what kind of lethal damage 1033 00:36:01,159 --> 00:36:02,827 your nimchas will do. 1034 00:36:02,827 --> 00:36:05,163 I will take your weapon and deliver some lethal blows 1035 00:36:05,163 --> 00:36:06,665 on this boar carcass. 1036 00:36:06,665 --> 00:36:08,375 Ryan, you're up first. You ready for this? 1037 00:36:08,375 --> 00:36:11,002 ‐ Make some barbeque cut. ‐ All right, let's try. 1038 00:36:11,002 --> 00:36:13,171 ‐ Seeing the boar carcass, 1039 00:36:13,171 --> 00:36:15,006 I'm smiling from ear to ear. 1040 00:36:15,006 --> 00:36:18,343 I wanted to see him cut a boar carcass in half with it. 1041 00:36:18,343 --> 00:36:19,678 I know it's razor sharp. 1042 00:36:19,678 --> 00:36:22,681 [upbeat rock music] 1043 00:36:22,681 --> 00:36:29,688 ♪ ♪ 1044 00:36:35,527 --> 00:36:36,528 ‐ Good job. 1045 00:36:37,862 --> 00:36:39,072 ‐ All right, Ryan. 1046 00:36:39,072 --> 00:36:40,532 I don't know what's a bigger beast. 1047 00:36:40,532 --> 00:36:43,076 The boar carcass or your nimcha right here. 1048 00:36:43,076 --> 00:36:45,370 This is a heavy sword. 1049 00:36:45,370 --> 00:36:48,081 Everything about the weight that you have on this 1050 00:36:48,081 --> 00:36:50,875 allows for a very, very deep cut. 1051 00:36:50,875 --> 00:36:53,044 But it's a lot of work because of the weight. 1052 00:36:53,044 --> 00:36:54,754 It's very forward‐heavy. 1053 00:36:54,754 --> 00:36:57,841 But overall, it will KEAL. ‐ Thank you. 1054 00:36:57,841 --> 00:36:59,008 ‐ All right, Steve, your turn, sir. 1055 00:36:59,008 --> 00:37:00,009 You ready? ‐ Yes, sir. 1056 00:37:00,009 --> 00:37:02,095 ‐ Let's do this. 1057 00:37:02,095 --> 00:37:03,263 ‐ I'm excited. 1058 00:37:03,263 --> 00:37:04,889 Ryan's blade cut well, 1059 00:37:04,889 --> 00:37:07,058 so I know I've got some competition here. 1060 00:37:07,058 --> 00:37:08,393 Mine better perform. 1061 00:37:08,393 --> 00:37:11,396 [upbeat rock music] 1062 00:37:11,396 --> 00:37:18,403 ♪ ♪ 1063 00:37:21,948 --> 00:37:23,575 ‐ [laughs] 1064 00:37:23,575 --> 00:37:24,951 ‐ All right, Steve, 1065 00:37:24,951 --> 00:37:27,162 let's talk about your nimcha right here. 1066 00:37:27,162 --> 00:37:29,914 First up, the handle construction. 1067 00:37:29,914 --> 00:37:32,167 It's smooth. It's not blocky. 1068 00:37:32,167 --> 00:37:33,960 So I like that you have it ovoid over there. 1069 00:37:33,960 --> 00:37:35,712 And marries in. 1070 00:37:35,712 --> 00:37:37,797 Before I started testing, 1071 00:37:37,797 --> 00:37:40,175 your blade has a little bit kick‐off to the side. 1072 00:37:40,175 --> 00:37:43,219 But after the test, it stayed the same. 1073 00:37:43,219 --> 00:37:47,056 Your edge, with a thinner profile like that, cuts deep. 1074 00:37:47,056 --> 00:37:50,894 Also, it is a much lighter sword 1075 00:37:50,894 --> 00:37:52,479 than your competitor's. 1076 00:37:52,479 --> 00:37:54,230 I can control with every slash. 1077 00:37:54,230 --> 00:37:57,275 Overall, sir, your blade feels good. 1078 00:37:57,275 --> 00:37:58,526 It will KEAL. 1079 00:37:58,526 --> 00:37:59,778 ‐ Thank you, sir. 1080 00:37:59,778 --> 00:38:03,364 ♪ ♪ 1081 00:38:03,364 --> 00:38:05,533 ‐ Bladesmiths, welcome to the strength test. 1082 00:38:05,533 --> 00:38:07,952 The pillar and pot chop. 1083 00:38:07,952 --> 00:38:09,746 To test the strength and durability of your edge, 1084 00:38:09,746 --> 00:38:11,748 as well as the overall construction of your nimchas, 1085 00:38:11,748 --> 00:38:13,792 I'll be chopping into these pots and pillars. 1086 00:38:13,792 --> 00:38:15,210 Remember, this test is all about 1087 00:38:15,210 --> 00:38:16,669 what the targets do to your blades, 1088 00:38:16,669 --> 00:38:18,838 and not what your blades do to the target. 1089 00:38:18,838 --> 00:38:20,423 Ryan, you're up first, are you ready for this? 1090 00:38:20,423 --> 00:38:22,926 ‐ Tear it up. ‐ All right, man. 1091 00:38:22,926 --> 00:38:25,136 ‐ I know I'm behind the eight ball right now. 1092 00:38:25,136 --> 00:38:27,972 I need to perform really well in the strengthness test. 1093 00:38:27,972 --> 00:38:30,266 Hopefully, I'll pull back up into line with him 1094 00:38:30,266 --> 00:38:31,392 and be evened up. 1095 00:38:33,686 --> 00:38:37,106 ♪ ♪ 1096 00:38:37,106 --> 00:38:40,151 [upbeat rock music] 1097 00:38:40,151 --> 00:38:47,116 ♪ ♪ 1098 00:38:53,289 --> 00:38:55,375 ‐ Well, Ryan, in the strength test, 1099 00:38:55,375 --> 00:38:57,836 the edge that you have on here took a slight roll. 1100 00:38:57,836 --> 00:39:01,172 Like, I can't see it so much as I can feel it. 1101 00:39:01,172 --> 00:39:04,050 The rest of it is‐‐ is really wicked sharp. 1102 00:39:04,050 --> 00:39:06,511 It's still all in one piece. 1103 00:39:06,511 --> 00:39:08,179 Nice job. ‐ Thank you. 1104 00:39:08,179 --> 00:39:09,514 ‐ Steve, you're up next. You ready for this? 1105 00:39:09,514 --> 00:39:11,558 ‐ Yes, sir. ‐ All right, cool. 1106 00:39:11,558 --> 00:39:12,684 ♪ ♪ 1107 00:39:12,684 --> 00:39:13,768 ‐ I feel pretty good. 1108 00:39:13,768 --> 00:39:15,186 I think my blade cut 1109 00:39:15,186 --> 00:39:16,980 a little better than Ryan's maybe, 1110 00:39:16,980 --> 00:39:19,023 but he didn't have that canned flaw in his blade. 1111 00:39:19,023 --> 00:39:21,359 So I think I've got a blade that'll hold up to it. 1112 00:39:21,359 --> 00:39:24,404 [dramatic music] 1113 00:39:24,404 --> 00:39:31,411 ♪ ♪ 1114 00:39:35,206 --> 00:39:36,749 ‐ [bleep], man. 1115 00:39:36,749 --> 00:39:43,715 ♪ ♪ 1116 00:39:44,883 --> 00:39:46,759 ‐ Well, Steve, we got a problem, man. 1117 00:39:46,759 --> 00:39:47,927 ‐ [chuckles] 1118 00:39:47,927 --> 00:39:49,178 ‐ When I picked the sword up, 1119 00:39:49,178 --> 00:39:50,221 I was excited. 1120 00:39:50,221 --> 00:39:51,347 It's nice, light, 1121 00:39:51,347 --> 00:39:52,765 got a good shape to it. 1122 00:39:52,765 --> 00:39:54,684 But looking at your steel here. 1123 00:39:54,684 --> 00:39:56,811 It's a really big grain in here. 1124 00:39:56,811 --> 00:39:58,730 It really could have used more thermocycling. 1125 00:39:58,730 --> 00:40:01,232 I'm guessing‐‐I don't know how you‐‐how you treated this, 1126 00:40:01,232 --> 00:40:02,734 but... 1127 00:40:02,734 --> 00:40:04,277 however you did, it ended up brittle. 1128 00:40:04,277 --> 00:40:09,407 ♪ ♪ 1129 00:40:09,407 --> 00:40:10,909 ‐ Well, Steve, 1130 00:40:10,909 --> 00:40:13,077 your blade has suffered a catastrophic failure 1131 00:40:13,077 --> 00:40:14,621 during our strength test, 1132 00:40:14,621 --> 00:40:16,414 and can no longer continue with testing. 1133 00:40:16,414 --> 00:40:19,208 Therefore, I'd like to invite you to shake our hands, 1134 00:40:19,208 --> 00:40:22,587 shake your competitor's hand, and then please exit The Forge. 1135 00:40:22,587 --> 00:40:23,588 ♪ ♪ 1136 00:40:23,588 --> 00:40:24,923 ‐ Congratulations, man. 1137 00:40:24,923 --> 00:40:26,966 I'm disappointed my blade broke. 1138 00:40:26,966 --> 00:40:28,551 I didn't wanna go out that way. 1139 00:40:28,551 --> 00:40:30,011 But it is what it is. 1140 00:40:30,011 --> 00:40:31,638 Thank you. 1141 00:40:31,638 --> 00:40:32,889 I just must have got my heat treat wrong. 1142 00:40:32,889 --> 00:40:34,557 Nobody's fault but my own. 1143 00:40:34,557 --> 00:40:36,684 I didn't win the competition, 1144 00:40:36,684 --> 00:40:39,562 but I gained so much more than I lost here. 1145 00:40:39,562 --> 00:40:42,357 I'm gonna walk away here with my head held high, 1146 00:40:42,357 --> 00:40:44,984 and it's gonna make me a better bladesmith for it. 1147 00:40:44,984 --> 00:40:46,986 I've really learned a lot. 1148 00:40:46,986 --> 00:40:49,822 ♪ ♪ 1149 00:40:49,822 --> 00:40:51,366 ‐ Ryan, congratulations. 1150 00:40:51,366 --> 00:40:53,117 You are the Forged in Fire champion, 1151 00:40:53,117 --> 00:40:54,911 and that is a title that comes with a check. 1152 00:40:54,911 --> 00:40:56,162 Go ahead. You can smile. 1153 00:40:56,162 --> 00:40:57,455 ‐ [chuckles] 1154 00:40:57,455 --> 00:40:58,748 ‐ For $10,000, brother. Good job. 1155 00:40:58,748 --> 00:40:59,791 [applause] 1156 00:40:59,791 --> 00:41:02,168 Come on. ‐ Thank you, sir. 1157 00:41:02,168 --> 00:41:03,378 ‐ Good job, my friend. ‐ Thank you. 1158 00:41:03,378 --> 00:41:04,879 It's not how I wanted to win 1159 00:41:04,879 --> 00:41:06,839 this competition, but you know, 1160 00:41:06,839 --> 00:41:08,341 it is what it is. 1161 00:41:08,341 --> 00:41:10,134 First thing I'm gonna do is hug and kiss my wife. 1162 00:41:10,134 --> 00:41:12,470 And love on the kids and play with them. 1163 00:41:12,470 --> 00:41:13,638 And get right back in the forge. 1164 00:41:13,638 --> 00:41:15,640 There's no sleep for the wicked. 1165 00:41:15,640 --> 00:41:21,938 ♪ ♪