All language subtitles for Forged.in.Fire.S09E08.720p.WEB.h264-BAE

- I'm gary graham
from elkmont, alabama.

12 days after I turned 18,
I enlisted in the army,

Flying uh-60 black hawks.

Started making my first blade

After I got home
from deployment,

And it continued to grow
to a small business now.

- My name's eduardo sol.

I am original from mexico.

I moved to the u.S.
"cause I was

A foreign exchange student
during college,

And I met the woman
of my dreams.

She got me into blacksmithing,
and I got hooked on knives.

- I'm matt aaron.
I'm 31 years old.

I use bladesmithing as a way
to supplement my hobby

As an armored combat enthusiast.

Being able to create
my own weaponry

To a historical spec certainly

Keeps my creative juices
flowing,

And it keeps some money
in my pocketbook.

- I'm josh langpit.
I am from newport, virginia.

I got my start in bladesmithing
just before 16.

My dad handed me a fantasy
novel that a character

Made a sword using a volcano.

I cried bs at that point.

He asked me
to go do some research,

And I found out
that it's possible,

And that kinda set things
in motion from there.

- Well, bladesmiths,
welcome to the forge.

You're here to test yourselves
and your bladesmithing skills

Against each other
and against our clock.

Now, we've got
three intense rounds

Of bladesmithing competition
set up for you.

At the end of each one,
I'm gonna ask you

To present your work
to our panel of expert judges.

Now, bladesmiths, keep in mind
they're the ones

Who will be
wielding your blades,

Testing them,
and making the decisions

As to who's
gonna be leaving here

With the title of
"forged in fire" champion

And a check for $10,000.

But bladesmiths,
today in this competition,

We're gonna be paying tribute

To some badass cowboys
from south america:

The gaucho.

Smiths, we want you
to build this.

The gaucho knife.

The gaucho knife,
also known as the facon,

Got its name
from the nomadic cowboys

Of argentina and uruguay,
who made it popular.

Tracing its origins
back to the 19th century,

This weapon features
a sharp single edged blade

Long enough
to deliver lethal slashes.

Its short enough
to be easily concealed,

Making it the perfect weapon
for the gauchos

To use in close quarter combat

Against the spanish soldiers

During the war of independence.

While this knife is known
as a fighting knife,

The gauchos still use it
for hunting today.

Now, smiths,
to build this iconic knife

You're gonna need
what is on your anvils

Under that cloth.

So go ahead
and remove it for me.

What you see there is a bar
of 1084 high carbon steel

And next to it,
two bars of mild steel.

We want you to build
your gauchos

Using the san mai technique.

That is high carbon sandwiched

In between
two bars of mild steel.

Your blade length measured
from tip

To where the cutting edge ends

Needs to be
between 11 and 13 inches.

And you need to have
an integral bolster.

Now, by the end
of the first round,

You have to have your blades
quenched,

Hardened, and acid etched.

- I've never made
a gaucho knife before.

The challenging part is,
its all one piece construction,

Having that bolster separated
from the blade

And be able to get
your tang out of that.

And not to make
your bolster too small.

You can't put material back on,

But it's easy to mess it up
and make it too small.

So metal management
is the key to this competition.

- Now, moving on into round two

For the three of you
who join us,

We're gonna ask you
add handles to your blades,

Turning them
to fully functioning weapons.

You're gonna hand your blades
over to our judges,

And they're gonna check
for strength and durability

In a wooden gate chop.

And then see
how your edges held up

In a gaucho blanket slice.

You guys, you have three hours
on the clock.

Good luck and saddle up,
'cause your time starts now.

All right, I love that blade.

- Now, you know what's
interesting about the gauchos

Is that it is a subculture
in south america

In brazil, argentina, uruguay,

And that is one of the things
that defines them.

It is part of their wear.

- San mai, I have made
quite a bit of it,

So I am ready to rock and roll.

The 1084, it is clean.

The mild steel is still rough,
so that will not forge weld,

So I clean off one side of each

Of the two mild steel bars

So they will mate perfectly.

- You don't need to clean
all sides of everything.

- So just a real quick pass.

- Yeah.
- Clean it up.

- That's really all it takes.

- I stack my steel
like a sandwich...

1084 is the meat,
the mild steel is the bread.

The good 1084 steel
is your cutting edge.

That'll hold.

The mild steel is nice and soft
and ready to absorb any blows.

I feel great.

I think I set myself up
for success.

- San mai is a process I use
quite a bit in the forge,

So I really lucked out
with this challenge.

The first thing I need to do

Is get the two pieces
mild steel cleaned up.

I don't wanna take any chance
of a delam during my weld.

- Gary went straight back
to the mig welder,

And he's putting it together.

- I think the crossover
between flying helicopters

And bladesmithing
is the attention to detail.

You got to be mission oriented
and know the time on target

That you've got to be there,

And it's the same
with this competition.

You got to break down on legs
of what you've got to do

To get to the next step,

And you got to be
on time in three hours.

- I am familiar
with the san mai technique,

But I have not made
the gaucho knife.

I've seen them.

Welding!

- Having done "forged in fire"
in latin america,

I actually got to be exposed
to the gaucho knife

Because we had a contestant
that was a gaucho,

And he made a gaucho knife.

- It's time to get ready
to set the weld.

My biggest concern
is making sure

My weld set off the get go.

With the san mai construction,

You don't have that many layers
to back up any delaminations.

You have two welds, and those
two welds have to hold.

- You start hammering
on that cold,

Your chances of popping those
two welds really goes up.

- Billet appears to be right
at about

Where I think
welding temperature is at,

So I'm going to set
my welds nice and light.

Just nice, even taps to get
everything stuck together.

My welds are looking
pretty good.

Right back into the forge
to keep it hot.

And now we wait.

- I think the most
difficult aspect

Of the entire competition
is that time constraint.

Also, I don't have
much practice in a gas forge.

I exclusively use coal.

- Josh is setting his
first weld with a hand hammer.

- Yeah.

- There's a little bit
more propensity

Of weld flaws if you do that.

- Bladesmiths, you only have
two hours left

To finish your gaucho.

- Things are looking good
at this point.

I go to the press, and I do
some nice gentle presses

To get it welded together.

- And when I see that
first weld, I wanna see

That billet the same color
as the inside of the forge.

- Well, he wasn't quite there.

- He's pressing everything down
pretty cold.

All you're doing is building
stress in the steel.

- I look at my layers,

And I don't see any shadows
between those pieces,

So I'm confident
my forge weld was stuck.

- What makes a gaucho knife
unique is that integral bolster

At the back of the blade.

It acts as both
part of the handle

And a guard as well.

- I would definitely start out
by isolating that bolster.

Whether I form it immediately
or not, I'd isolate it.

- I am isolating my bolster
from the rest of the blade.

I use the corner of the anvil
to kind of mark it

And make
a nice little step down.

Everything looks good to my eye,

And I just need to shape
the rest of the blade.

- This challenge
was made for me.

I have made these knives before,

I have actually met gauchos,
and I know I can do this.

The trick about forging
an integral bolster is,

It's all the same metal.

If I'm not careful,
it will be lopsided

And can get me sent home.

- On first appearances,
the gaucho knife

Seems relatively simple,
but when you get into it,

Especially around the bolster
and the heel area

Of this knife,
you really got to know

How to move the middle
where you want it.

- I get a rough blade profile,
and I am ecstatic.

- As I start to shape
this blade,

I'm really concerned about
that bolster in particular.

So I wanna isolate that area
so that I make sure

That I leave enough material
there that I can get that

And the length I need
to make a through tang.

- It seems that josh is only

Using his hammer
in this process.

- You know, with a timed
competition there comes a point

You're just using too much time
and moving too little metal.

- I'm used to hand hammer
and hand tooling.

While I really do want
to represent that skill set,

I don't have that luxury here.

I'm starting to feel
the pressure of the clock,

And as I'm working that
bolster by hand, I realize

That if I use a press,
I can save time

And a whole lot of effort.

Looks like it's coming together
just fine.

- Bladesmiths, you are down
to one hour.

- I was on forging,
the tang's gone big blue,

I look and I see
the end of my tang

Starting to mushroom out.

Damn it.

Obvious cold shuts
on the end of it.

If I continue without
getting rid of it,

It'll progress all the way up
into delam end on my bolster,

And I would have to start out
with a new billet.

- So working his billet cold
has definitely bit gary.

- I decided to tack weld that up

To eliminate that problem
so I wouldn't have

Any future problem
with the end of my tang.

Time's ticking, and I need
to forge out my blade.

I'm feeling worried.

- The san mai has a tendency
to warp in the quench,

Especially if you have heated
one side more than the other

Or you have thinner mild
on one side than the other.

So to mitigate this,
I wanna quench thick

And then grind thin.

- Look at matt's blade
right now.

That is way above where
it needs to be to be quenched.

- Yeah, with the wrong
temperatures,

We've seen them split apart.

- So matt's in the oil.

- Everything's straight.

I have a lot of weight
on this blade,

So I let it cool down
as much as I can.

I'm gonna hog
a lot of metal off.

- Everything is rough shaped,
the blade is ready to rock.

- Eduardo just quenched
at the right temperature.

- The hardest part is over.

My blade is hard.

Now I just need to pretty
to this bad boy up.

I hit the grinder,
and I'm just digging into it.

I stop to check parameters.

- Something's going on.

I grind my blade
under 11 inches.

I no longer meet parameters.
- Uh-oh.

If he's short,
then he absolutely

Has to get that length
in order to move forward.

Oh.

I can't figure a way out
without putting this back

In the fire to stretch my steel.

My blade is 90% done, and I
have to go back in the fire.

I'm worried that
I don't have the time

To get this blade done.

- I have to get
back in the fire.

- He has to get
within parameters.

- I'm very overwhelmed,
but I'm up against the clock,

So I just gotta get this blade
ready to requench,

Making sure I have way more
steel than I need.

- Bladesmiths,
you have 30 minutes.

- Josh, if you look
at the profile he's got,

The blade profile
is pretty spot on.

- Jeez, that's hot.
- Holy...

- Everything looks like
its good,

But it does have a little bit
of a snake to it.

But I really feel like
it's still within grindability.

Hopefully, I'll be able
to get it done.

- I'm ready for quenching.

- Eduardo's in the oil,

Extremely hot, we might see
some splitting going on.

- It comes out straight,

And I'm well within
my parameters.

I am so relieved.

But I still got a lot of things
to do and not much time left.

Whew.

- I'm on the grinder
and getting towards the end,

So it's time to quench.

- There we go.

- Nice color.
- Nice.

- All right,
four quenched blades.

- I've got one little warp,
so I go over

And correct that on the anvil.

I put a little pressure on it,
straighten it up.

I still had enough meat
left on it to straighten it out

On the final grind before
turning it to the judges.

- As I'm grinding the blade
for a second time...

Oh.

I feel a pop.

There is a seam
from the top of the blade

All the way to the bottom.

I have a catastrophic failure.

- We've probably seen dozens
of times when we ask a smith

To do the san mai technique,

The problems
really start to arise

When they hit the grinder.

- I have to basically
re-forge weld my san mai.

I'm thinking
I'm gonna get sent home.

I don't have the time
to start over,

But I am not giving up.

- It's not a good sign
for eduardo, man.

He's in
for his third quench now.

- With a third quench,
the grains are going to expand,

My blade has become brittle.

I am terrified that this is
gonna just shatter like glass,

But I don't have a choice.

I have to get this blade
to a grinder

And finish this blade
and meet parameters.

- Bladesmiths,
you have 15 minutes.

- In order to finish off
this blade, I need to pull

The mild steel back
and reveal the core metal.

As I'm grinding away,
there's a frickin' crack

Almost the whole length
of the spine.

- Oh, what is going on here?

- Given the time constraints,
I'm gonna go over,

Put a bead of weld
right down the spine of this.

That's gonna at least give me
a point of contact

So that I don't pop loose
anything else in the billet.

- When you have a delamination
on the blade,

One of the things you really
have to be smart about

Is cleaning it out,
or what you're gonna have

Is rust forming down
at the base of that crack.

So that mild steel weld
at the top is gonna keep it

From cracking there.

That crack might open
from the edge now.

- I'm fairly comfortable that
I've alleviated this crack,

But right on the edge,
there's this travelling crack.

I'm starting to run out of time,

So I can't redo this again.

I think I'm pretty okay
in just grinding this back.

Hopefully it doesn't come back
and bite me in the butt.

- I get my blade to a shape
that I like.

So I put it in the etch
so that I can see

That I've exposed
high carbon material

All the way down my blade.

I've got high carbon steel
all the way down the middle.

Everything looks right
until I flip it over.

I have a crack right down
the center of my blade.

- This could be disastrous.

- We talk about the problems
that develop with san mai,

Some of the splitting
that we see,

Most of that comes from the fact

That the smiths
are quenching these blades

Hundreds of degrees hotter
than they should be quenched.

- Yep.

- It's looking deep,
and I don't know

If I have enough material
to grind this thing out.

If can't get it out,
that could send me home.

So I run over to the mig
station to keep the crack

From spreading any further.

I think I've managed to stop
the crack from spreading.

It's back to the grinder again

To get as much of that
blobiness out of it as I can.

- Five, four, three, two, one.

Bladesmiths, the first round
of this competition is over.

- I am elated that I am
turning in a blade.

But with a third quench,
the grain of this blade

Has expanded and contracted.

I am very concerned
that my blade

Is gonna be a lot rougher
than my competitors.

- Bladesmiths, in the first
three hours

Of this competition, you took
three pieces of metal

And turned them into your own
renditions of the gaucho knife.

The time has come
for your first critique,

And unfortunately,
an elimination.

Gary, you're up first.
You ready?

- I'm ready.
- Please present your work.

- All right, gary,
you've got a nice form

Of the gaucho knife.

And you were very careful
with your temperatures,

Especially when you quenched,
so the steel looks pristine.

The bolster looks great.
Overall, clean work. Good job.

- Thank you.
- Eduardo, how are you feeling?

- Pretty good.

- All right,
please present your work.

- All right, eduardo,
it's pretty much spot on

As far as the profile goes.

If you move forward,

There's the slightest crack
on the steel here.

I have a feeling
it's very close to the surface

And not very deep, very slight,
but would be a good idea

To address,
but it's looking good.

- Matt, how are you doing?

- Pretty good,
all things considered.

- All right,
please present your work.

- All right, matt,
first thing I feel

When I pick up your knife
is that it's got

A lot of mass left,
a lot of grinding ahead of you

If you move forward from here.

Your forge welds look good.

But the one thing, though,
that is alarming to me

Is that there is a crack
along the edge of your blade

Deep enough
and wide enough for me

To get my fingernail
deep in there.

That's in a very critical spot,
and it's quite deep,

And it's right in the center.

- Josh, last but not least,
you ready?

- Indeed.
- Please present your work

- All right, josh,
after you quenched,

You were able to identify
a crack on your spine.

You welded that in.

In doing so,
you opened up some cracks

On the edge
where it's really critical.

The good thing is, you were
able to grind out most,

And you have a strong edge here.

Should you move forward,

There's a lot of grinding
right here

To get it even, but good job.

- Well, guys, in the
first round of competition,

You guys all turned in blades
that met parameters,

So you all have something
to be proud of,

But the judges
had a decision to make,

And the bladesmith that's not

Gonna be moving forward
in this competition is...

Matt.

Unfortunately, you didn't
make the cut.

Dave baker is gonna
tell you why.

- Matt, it really comes down
to that crack

Being dead center on your edge.

It's splitting the actual steel
right down the middle.

There's really not
an easy fix for that,

And that's why
we're letting you go.

- I understand.

- Well, matt, you're very
clearly a talented smith.

But unfortunately, your time
in this competition has ended.

I'm gonna have to ask you
to please surrender your work

And step off the forge floor.

- I did not see that crack
until I etched again.

- Really good-looking
profile, matt.

- Thanks, guys.

So there's really very little
I could have done about it.

But the experience here
was a blast.

- All right, bladesmiths,
congratulations.

The three of you are joining us

In the second round of the
gaucho knife competition.

Now in this round, we ask you
add handles to your blades,

Turning them to fully
functioning gaucho knives.

But first, you got to fix
any of the issues

That the judges brought forward.

The good news about this round,
guys, is the pantry is open.

Bad news is, the only thing
you can use from there

Has to be sourced
from an animal...

Bones, antlers,
horns, or leather.

When this round is complete,
we're gonna test your blades

For strength and durability
in a wooden gate chop.

Then they're gonna check
your edge retention

In a gaucho blanket slice.

We've got two hours
on the clock for you,

So good luck.

That time starts now.

If you guys were in this
competition right now,

What handle material
would you be seeking out?

- There are a number of antlers
over there

That are perfectly usable.

And the nice thing
about antler is,

Is you need to drill
a hole through it,

Taper the ends a little bit,
and you're done.

I mean, that's all that is
right in the example.

- There's some
warthog intestine.

- I've never used that stuff,

So I'm trying to stick
to what I know.

- All right, so it seems gary's

In a pretty good spot right now.

- Oh, yeah.
- Oh, yeah, by far the best.

- I feel pretty confident
to be able to take my time

And pace myself
through round two.

I like that.

I select a piece
of water buffalo.

I knew that it would be
easy to grind down

And get to the shape
I was looking for.

- A water buffalo horn
is really tough.

You can throw it on the ground,

It's bomb proof,
it's waterproof, good stuff.

- I drill into my horn,

Fit it up with my tang,
I'm feeling good.

That's pretty nice.

So now I can get it
into the glue

Up on the handle.

- The judges told me

That there was
a slight crack on the blade.

So I've got to really make sure
I get that crack ground out.

- Something josh could do that
would help him a lot,

Is do a hollow grind
on that blade.

Then he'd be pushing
that crack higher and higher,

Come back, reweld that crack,

Then marry that all in
with that faded hollow grind.

- I did the best I could
to grind the crack out,

But it's still there.

I can feel the time
running down on me.

I really have to move on
to the handle.

- I'm very relieved
I've made it this far.

Top of the list.

I've got to address the minor
crack on my cutting edge.

- Eduardo, as he grinds,
that crack could get worse,

Or if it's a surface crack,

As he grinds,
that could go away.

- Perfect.

I am so relieved
everything has held up.

There are no cracks, and I have
a great, solid blade.

- I've got my handle
on my tang, and I know

I've got to add
a mechanical bond

To hold that butt cap
onto the handle.

- He's gonna peen the tang over.

Yeah, there you go.

- I'm really concerned about
ruining my epoxy and my handle

By getting the tang too hot.

If I destroy my epoxy bond,

During impact,
that butt cap can come off,

It is a critical failure,
it could send me home.

I'm hoping that it's strong
enough bond to hold

That butt cap onto the handle.

All right.

- All right, guys,
you're halfway

Through this handle round.

You have one hour left.

- I am not a fan
of using animal products

Because it stinks
to high heaven.

Oy.

But the judges get
what the judges want.

It's time to stack this up,
so the leather goes on

Because I need something soft
to mold to my integral bolster.

The leather does that,
and then I put my bone

And then more pieces
of stacked leather.

That way, when I peen this down,

There is no chance
of anything splitting.

- He is using leather
as a transition piece,

Then it looks like
he's gonna put a butt cap

On the end of that.

- Okay, so does that work?
- Yeah, it'll work.

- I know I'm gonna need that
five minute epoxy to harden

Before I get
that butt cap peened on.

- Well, I get the handle
all fit up, and I can work

Over the peen
on the end of the knife.

- It works better
if you don't have epoxy.

You can see
that little flame pop up

Where he's burning the glue.

- Everything is bent over
just well enough

So I can start
grinding this to shape.

Ah, you.

- Oh.
- Yeah, that's not good.

- Unfortunately,
what we've seen a lot of

Are smiths heating things
over and grinding away

All the work that they just did.

- The brass piece has melted
the glue 'cause it got hot.

'cause the butt cap got hot,

And it's starting to shift.

What can I do?

If I don't have
a really tight fit,

Then I'm definitely going home.

Time's running out,
and I'm starting to feel

A little bit frustrated.

I'm gonna have to apply
some superglue and hope that

That is gonna make everything
solidify a little bit.

- Krazy glue is a quick thing
to use as a filler

But not necessarily something
to hold tightly together

Because sometimes,
I've seen you guys,

You just snap it,
the vibration makes it brittle.

- Yeah.

- Bladesmiths,
you have 20 minutes left.

- C'est la vie.

- I've got to have a good
convex edge on my blade.

I don't wanna go into
the testing with a blade

That's not gonna hold edge,

But I don't want that edge
to be so thin

That it's gonna shatter
or chip during the test.

- A wood chop,
it's a tough test,

But a properly done edge,
chop wood all day.

- I've got a good, sharp,
shaving blade.

You know, I'm pretty proud
of the blade that I made

Within the timeframe
that I had to do it.

My tip's sharp.

- Looks like eduardo
got that tang peened over.

- The blade's pretty much
where I need it.

And I gave a five minute epoxy
enough time to harden

So it's just straight
to the grinder,

And I'm ready to start
on my handle.

That way, it's as smooth
as a transition I can get.

There's nothing that's gonna
bite the judges.

Look at that.

- I feel fairly confident in
the construction of the blade.

So I go ahead
and start working on

Putting an apple seed edge on
and buffing things up.

- Right now,
it looks clean and shiny.

- It looks really good.

- My biggest concern
with josh's blade

Is that I haven't seen him

Really go to the welder
and weld up that crack.

- Five, four, three, two, one.

Bladesmiths, put down your tools

And turn off your machines.

This round of the competition
is over.

- My blade winds up feeling
pretty nice in my hand,

But it's an ugly pig
when you look at it close.

Hopefully, those flaws
don't come back

And bite me in the butt.

- Bladesmiths,
welcome to the strength test,

The wooden gate chop.

To test the strength
and durability of the edge

As well as
the overall construction

Of your gaucho knives,

I'm gonna be chopping and
stabbing into this here gate.

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

- Let's get it on.
- All right.

- When he swings the knife,
his feet come off the ground,

He hits so hard.

So really hope that peen
is good on my butt cap

And I don't have
any catastrophic failures.

I'm more nervous
than a house cat

On a porch full
of rocking chairs.

- Well, gary, that's a good
looking gaucho knife, man.

The tip is nice
and acute for stabbing,

It held up well, and your edge
also held up really well.

So well done.
- Thank you.

- All right, eduardo,
how do you feel?

Um.
Beat it like it owes you money.

- I'm very nervous.

I did quench three times.

There is a lot of stress
in my blade,

And I'm afraid that when
ben abbott strikes that fence,

It's gonna explode.

- Well, eduardo, first things
first, you're all in one piece.

Everything's still tight.
Nice job.

Your edge just hit
this one spot here.

It's just got a little bit
of a glinting to it,

But you have
a relatively obtuse edge,

So the rest of it held up great.

Nice job.
- Thank you.

- All right, josh, you're up.
You ready for this?

- Whether I am or not,
let's do it.

- All right, let's do.

- My biggest concern
going into testing

Is really that
the handle holds up,

It doesn't wiggle apart,
doesn't rotate in their hands.

- Well, josh, it held up great,
so nice job on that.

The crack you had in your steel
is still present,

Which is now
kind of full of sawdust.

But it's not opening up;
I didn't see it move anywhere.

Your blade kind of meanders,

It's sort of starts off
going left

And then kind of curves riding
in and then rights itself.

When coupled with a handle
that's pretty round,

I did have to adjust once or
twice to get it back on line,

But in general, you held up
well on the strength test,

And nice job.

- Thank you.

- Welcome to the sharpness test,

The gaucho blanket slice.

Now to find out
how sharp your weapons are,

I'm gonna cut through
these gaucho blankets.

Gary, you're up first,
ready for this?

- I'm ready.
- Lets do this.

All right, gary, let's talk
about your gaucho knife here.

Your edge is sharp.

Now it may look like rips;

Those are actually
very clean cuts.

Overall, sir, your weapon,
it will cut.

- Thank you.

- All right, eduardo,
your turn, so are you ready?

- Yes, sir.
- Let's do this.

- All right, eduardo,
let's talk about

Your gaucho knife here.

Even though you have
an obtuse grind,

It cut easily
through this gaucho blanket.

Overall, sir, your weapon,
it will cut.

- Thank you so much.

- Josh, your turn, so you ready?

- Yee-haw.
- Yee-haw.

All right, josh, let's talk
about your gaucho knife here.

Now your edge
also has an obtuse grind.

But it is sharp enough to cut
cleanly into this blanket.

Overall, sir, your weapon,
it will cut.

- Thank you, sir.

- All right bladesmiths, well,
the gaucho knife challenge

Was definitely a difficult one.

But you all gave us blades that
made easy work of our testing.

But in this competition,
only two of you can join us

In the third round
and our judges,

They made a decision.

The bladesmith leaving
the forge is...

Josh.

You fought hard,
and you gave us a blade,

But unfortunately
it didn't make the cut today.

And ben abbott's
gonna tell you why.

- Well, josh, you came out
of round one

With a pretty severe crack
in your blade.

And you did a great job
in minimizing that crack,

But you didn't
remove it completely.

And in doing that,
you really made your blade

Take quite a bit
of warping and wobbling,

And it's for those reasons
we're gonna let you go.

- I totally understand that.
Thank you so much.

- Well, josh, we all wanna say
you're a talented smith

And you have what it takes
to be in this forge,

But unfortunately, your time
in this competition has ended.

I'm gonna have to ask you
to please

Step off the forge floor.

- I've got that little
disappointment

That I'm not able to move on
and really do something

Spectacular
with a historic blade.

But at the same time,
it surprised me

All to pieces
how well my blade performed.

- All right, gary, eduardo,
congratulations, guys.

Your hard work has paid off,

And it is now down to the two
of you battling it out

For the title
of "forged in fire" champion

And that check for 10 grand.

Now because this competition
is all about iconic weapons

From south america,
we're sticking with that theme.

We're giving you four days
to build this...

The argentinian saber.

- The argentinian saber was
a fierce 19th century weapon

Used by the cavalry soldiers

Known as
the argentinian grenadiers.

These mounted warriors
used the lightweight

Single edged blade
to deliver swift

And lethal slashes
against enemies

While the large hilt
protected their hands.

After their crucial service

In the argentinian war
of independence,

The grenadiers
were given the honor

Of becoming
the presidential escort guard.

Today, these elite soldiers
still protect the president

With this powerful saber
at their sides.

- Your blades need to have a
slightly curved pipeback blade

That measures between
35 and 37 inches.

Now down to the hilt,

You guys need to have
an asymmetrical

Bell-shaped guard
with multiple piercings.

And to finish it off, you need
to have a pistol grip handle.

- I've never forged
anything this long,

But I'm gonna make
the best argentinian saber

Because I wanna win so bad
I can taste it.

- All right, guys, we will
see you in four days.

- Good luck.
- Well, stay safe, dude.

- I'm here in my home forge,

Ready to make
an argentinian saber.

Alrighty. Here we go.

My goal for today
is to have a hardened blade

Ready to start grinding
on it tomorrow

And starting to make it pretty.

My concern
is the pipeback spine.

There we go.

I never knew
that existed until today.

The biggest challenge
is putting in the curve

That's a requirement

While still keeping
the pipeback spine intact.

Forging has gone really well.
That's good enough.

It's close enough,
and I am ready for the quench.

Whew.

The blade is hard.

The blade is straight.
And I'm exhausted.

- I'm here in my home shop
in elkmont, alabama.

I'm getting ready to get started

On the argentinian saber.

Mississippi 5160.

By the end of day one, I wanna
have my blade forged out.

Then stretch the rod
out a little bit.

You see the pipe coming out.

So far, so good.

A forged blade out that
the length I want out of it,

You gotta force the shape.

Drawing it out with my dies

And verify that
everything's nice and even.

It's looking good.

- Day three,
yesterday was fantastic.

I got the blade completely done.

All I need to do now
is get started on my hilt,

And one of the parameters

Is drilling the piercings
in the hilt.

There's that disk.

These rotary discs
are literally exploding

As soon as I put them on.

The guard is too hard

For the rotary discs
to cut through.

This one line right there
took 2 1/2 cutting discs.

I am extremely
aggravated by this.

This is supposed
to be quick and easy.

I am burning through my day.

I'm falling behind.

I hope I'm gonna
have enough time.

Alrighty,
now to make that pretty.

I finally finish the piercings
on my guard.

I am down to
a single rotary disc left,

But I'm running out of time.

I need to fly through my handle.

Hopefully, everything's
gonna marry up perfectly.

That's it.

Overall,
I'm still on schedule somehow.

- Starting day three.

Yesterday, I got my blade
finished and quenched.

It's time to go
and sharpen the blade.

So I'm at the point now
I can go out

And do some testing
with my blade.

Whoops. Missed part of it.
I bent my blade.

I come out with a blade
looking like a boomerang.

I can't salvage this blade

Because I don't wanna risk
any grain growth in the blade.

And now I got to start over.

I only got one more day
to get it done.

Hopefully, that's enough time
to forge a new blade.

- We should have
the process down pat now.

We're good on parameters.

It's been a hell of a day,

But at the end,
I've got a quenched blade.

This blade looks a lot better
than the blade

That didn't work out so great.

All right.

- Morning of day four and it's
time for some fit and finish.

After I peen this on
and close it,

I'm gonna grind
this extra steel off

So it's a much tighter
fit to the handle.

It's time to peen the guard
and then sharpen my blade.

That should be it.

It's really coming out great.

That is sharp.

- Day four, I feel
I'm in pretty good shape.

It's time for me to work
on my handle and my hilt.

I grab a piece of sheet metal,
cut out the shape that I want,

Then I start shaping it
in the swage block.

Now I'm gonna cut
these piercings into my hilt.

My plan to put
this handle together

And secure it properly is,

Is I wanna notch out my tang,

Weld in a machine bolt
with a spacer

So I can tighten it all up.

And the last thing I need to do

Is sharpen it
and assemble the sword.

That's it for round three.
It's in the judges hands now.

- Welcome back to the forge.

You just stepped in here after
four days at your home forges

Working on your very best
argentinian sabers.

But before we get into testing,
I wanna hear about the blades.

Gary, how'd it go for you?

- I started hitting some bumps,

And I made the decision
to forge another blade.

I used 5160 for the blade,
sheet metal for the guard,

And some mystery wood
for the handle.

- Eduardo, how about you,
how'd it go?

- Very stressful.
Lots of unknowns but good.

I used 80crv2 for my blade,

14 gauge steel
for my bell guard,

And padauk for my handle.

I can't wait for you guys
to mutilate it.

Awesome.

Gentlemen, your blades
look lethal.

There's only one way we know
how to find out

Which one of you
is gonna be leaving here

With the title of
"forged in fire" champion,

And that's by putting
your blades through some tests.

First, the keal with doug.

- All right, bladesmiths,
welcome to the keal test.

Well, it's time to find out

Just how lethal
your weapons are.

I'm gonna take your weapons
and deliver some thrusts

And slashes on this pig carcass.

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

- I'm ready.
- Let's do this.

- Since I've already warped one
blade during testing at home,

During testing at home,

I'm nervous as a cat
on a hot tin roof.

A pig's a tough animal,

And I don't want my
blade to crack.

I don't want it to warp,
and I don't want it to break.

- All right, gary, let's talk
about your weapon here.

First up, most of the weight

Is right in the very tip
of this blade.

But the saving grace for that
is that you have a nice handle

Right there
where I can grab on to it.

I can marry my hand,
it's all void,

And I've got full control
with this weapon.

As you can see,
those were very deep cuts.

Overall, sir, your weapon...

It will keal.

- Thank you.

- All right, eduardo,
your turn, so are you ready?

- I'm excited. Let's go.

- Let's do this.

- I know my edge is fantastic.

It can take a beating.
It's a killer blade.

I can't wait to see
what it can do.

- Gentlemen, I think
we have a problem here.

That's a very small handle.
My hand barely fits in there.

And when I'm swinging,

There was just no retention
or stop right here.

Especially in the slashes.

If you're thrusting it
with a forward width,

All that is on my wrist.

What do you think?

- I see what you're saying.

I can swing it out,
but I can't pull it back up

'cause
I don't have the leverage.

- Yeah, I'm looking
at my fingers doubled up.

The problem is,
is there's no space in there.

If it does cut loose,
that's breaking my hand.

- Is there any way to adjust
and make it fair?

- The problem with that is,
I can hold back

To make it work,
but now I'm holding back,

And that's not
an even test anymore.

- Okay, you guys all agree
the blade is not safe to wield?

- Yes.
- Definitely.

- Okay.

- Eduardo, we absolutely hate

To see a competition
end like this.

When wielding an edged weapon,

Safety is always
of the utmost importance.

Due to the small handle
you've presented

And the lack of retention
that it offers,

The judges have issued
a vote of no confidence.

They can't safely
test your weapon.

So unfortunately, your time
in this competition has ended.

I'm gonna have to ask you
to please

Step off the forge floor.

- Congratulations, buddy.
- Thanks.

- Thank you, though, eduardo.

- I'm crushed.
I'm disappointed.

I worked really hard for it
for it to not to get tested.

It fit my hand perfectly.

Every step of this competition
was a learning experience,

And I really think
I'm leaving a better smith.

- Gary, you are today's
"forged in fire" champion.

You got yourself a check
for $10,000.

Congratulations.

- Thank you.
I really appreciate it.

It feels great to be
a "forged in fire" champion.

- What are you gonna do
with the 10 grand?

Do you have plans?
- No, I'm sure my wife does.

I just want to savor this
for a while.

It was a lot of work
to get here.

It's been fun, I've met
a lot of great people,

And I've enjoyed it.

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