1 00:00:05,614 --> 00:00:08,399 [dramatic music] 2 00:00:08,530 --> 00:00:14,971 ♪ 3 00:00:15,102 --> 00:00:17,887 - My name is Alex Horn. I am 26 years old. 4 00:00:18,018 --> 00:00:20,585 I am super excited to test myself 5 00:00:20,716 --> 00:00:23,066 and see what this competition does. 6 00:00:23,197 --> 00:00:25,199 I love challenging myself and always trying something new, 7 00:00:25,329 --> 00:00:27,244 and just pushing my skill level. 8 00:00:27,375 --> 00:00:32,032 In the right moment, I'll blossom and shine. 9 00:00:32,162 --> 00:00:35,992 - My name is Kevin Burkman. I'm 49 years old. 10 00:00:36,123 --> 00:00:38,299 I retired from the Army after 24 years. 11 00:00:38,429 --> 00:00:40,953 My first knife that I got when I was in the military, 12 00:00:41,084 --> 00:00:42,520 I didn't like it, 13 00:00:42,651 --> 00:00:45,132 it didn't fit the gear that I had, so I made my own. 14 00:00:45,262 --> 00:00:47,873 And then I just started from there. 15 00:00:48,004 --> 00:00:49,919 - My name is Pat Biggin and I'm from Elkhorn, Wisconsin. 16 00:00:50,050 --> 00:00:52,356 I started bladesmithing when my grandpa gave me a knife 17 00:00:52,487 --> 00:00:55,011 that his dad made for him during the second world war. 18 00:00:55,142 --> 00:00:56,708 And I started getting interested 19 00:00:56,839 --> 00:00:59,320 in how the process was done, can I still repeat it. 20 00:00:59,450 --> 00:01:01,713 It's just kind of a way to pay homage 21 00:01:01,844 --> 00:01:04,107 to my great grandfather's work skill set 22 00:01:04,238 --> 00:01:05,935 and maintain the tradition through my family. 23 00:01:06,066 --> 00:01:08,677 - My name is Mike Benton. I'm 45 years old. 24 00:01:08,807 --> 00:01:10,113 I have a huge family. I have six kids. 25 00:01:10,244 --> 00:01:12,289 Four girls and two boys. 26 00:01:12,420 --> 00:01:14,770 So, being here, this is definitely a vacation. 27 00:01:14,900 --> 00:01:16,815 Yeah, yeah, my wife actually wanted to come. 28 00:01:16,946 --> 00:01:19,253 But my family is number one to me. 29 00:01:19,383 --> 00:01:20,602 I love my kids, I love my wife. 30 00:01:20,732 --> 00:01:21,994 I mean, they're the reason 31 00:01:22,125 --> 00:01:24,388 why I work so much every single day. 32 00:01:24,519 --> 00:01:27,522 - Bladesmiths, welcome to The Forge. 33 00:01:27,652 --> 00:01:29,654 Each of you is here to engage in three rounds 34 00:01:29,785 --> 00:01:31,787 of timed edged weapon making competitions 35 00:01:31,917 --> 00:01:34,485 specifically designed to test every aspect of your skills 36 00:01:34,616 --> 00:01:37,097 in front of a panel of expert judges that will tell us 37 00:01:37,227 --> 00:01:39,577 which of you is the next "Forged in Fire" champion, 38 00:01:39,708 --> 00:01:42,319 leaving here with a check for $10,000. 39 00:01:42,450 --> 00:01:44,930 Let's go ahead and meet those judges now. 40 00:01:45,061 --> 00:01:47,237 Up first, two-time Forged in Fire champion, 41 00:01:47,368 --> 00:01:48,717 Ben Abbot. 42 00:01:48,847 --> 00:01:50,936 Next, historic weapons re-creation specialist, 43 00:01:51,067 --> 00:01:52,112 David Baker. 44 00:01:52,242 --> 00:01:53,765 And last, edged weapons specialist, 45 00:01:53,896 --> 00:01:55,071 Doug Marcaida. 46 00:01:55,202 --> 00:01:57,073 Bladesmiths, today's competition 47 00:01:57,204 --> 00:01:59,119 revolves around barbarians, 48 00:01:59,249 --> 00:02:03,079 specifically, the Goths who sacked Rome in 410 A.D. 49 00:02:03,210 --> 00:02:04,907 Now, along the way, 50 00:02:05,037 --> 00:02:07,388 the Goths seized weapons of their adversaries 51 00:02:07,518 --> 00:02:09,955 and incorporated them into their own arsenals, 52 00:02:10,086 --> 00:02:11,870 and today we're going to ask you to incorporate 53 00:02:12,001 --> 00:02:14,786 these weapons into a billet 54 00:02:14,917 --> 00:02:17,224 from which you will forge one of these, 55 00:02:17,354 --> 00:02:19,226 a favorite of backstabbers everywhere. 56 00:02:19,356 --> 00:02:22,403 ♪ 57 00:02:22,533 --> 00:02:25,623 A pugio dagger. 58 00:02:25,754 --> 00:02:28,539 It is believed that the pugio was the weapon used 59 00:02:28,670 --> 00:02:30,498 by the senate conspirators to assassinate 60 00:02:30,628 --> 00:02:34,806 Julius Caesar on the Ides of March in 44 A.D. 61 00:02:34,937 --> 00:02:37,113 Your challenge here in the first round 62 00:02:37,244 --> 00:02:39,811 is to use a Hada technique to combine three or more 63 00:02:39,942 --> 00:02:42,162 of these weapons to forge a pugio 64 00:02:42,292 --> 00:02:44,207 that falls within the following parameters. 65 00:02:44,338 --> 00:02:45,948 The length of your blade must be between eight 66 00:02:46,078 --> 00:02:47,384 and ten inches. 67 00:02:47,515 --> 00:02:49,430 It must have a wasp waist 68 00:02:49,560 --> 00:02:52,084 and be at least two inches wide at the base. 69 00:02:52,215 --> 00:02:54,130 - I know nothing about barbarians 70 00:02:54,261 --> 00:02:56,350 and a very little bit about daggers. 71 00:02:56,480 --> 00:02:57,960 I've never made a dagger before. 72 00:02:58,090 --> 00:03:00,571 So I'm getting a little nervous. 73 00:03:00,702 --> 00:03:02,530 - You will have just three hours 74 00:03:02,660 --> 00:03:04,532 in this first round in which to complete your work. 75 00:03:04,662 --> 00:03:06,186 If you make it to the second round, 76 00:03:06,316 --> 00:03:09,014 you will have a chance to put a handle on your pugio, 77 00:03:09,145 --> 00:03:11,365 making it fully functional so that we can test it 78 00:03:11,495 --> 00:03:15,586 for strength and durability in a shield chop and stab, 79 00:03:15,717 --> 00:03:18,154 and for edge retention in rope slice. 80 00:03:18,285 --> 00:03:20,461 Bladesmiths, pay attention to the details. 81 00:03:20,591 --> 00:03:22,637 Failure to meet a single one of our parameters 82 00:03:22,767 --> 00:03:24,334 is grounds for immediate dismissal 83 00:03:24,465 --> 00:03:26,684 from this forge with no deliberation. 84 00:03:26,815 --> 00:03:29,774 Good luck, bladesmiths. Your three hours starts now. 85 00:03:29,905 --> 00:03:32,255 ♪ 86 00:03:32,386 --> 00:03:35,171 - All right, so these guys have to combine those steels 87 00:03:35,302 --> 00:03:37,869 into a Hada Damascus billet. 88 00:03:38,000 --> 00:03:40,655 Hada technique is really just layering 89 00:03:40,785 --> 00:03:42,526 of the same types of steel, right? 90 00:03:42,657 --> 00:03:46,487 - It's a really ancient technique of using up scraps. 91 00:03:46,617 --> 00:03:50,665 - We've got our smiths kind of disassembling some knives. 92 00:03:50,795 --> 00:03:52,884 Why aren't these guys just cutting off, like, 93 00:03:53,015 --> 00:03:55,800 shafts and blades and stacking that stuff up? 94 00:03:55,931 --> 00:03:57,802 - Because it's more fun hitting things with hammers. 95 00:03:57,933 --> 00:03:58,934 - Yeah. 96 00:03:59,064 --> 00:04:00,196 - Pros of the Hada technique 97 00:04:00,327 --> 00:04:02,198 is it's all the same type of steel. 98 00:04:02,329 --> 00:04:04,809 The downside is that I then have to make sure 99 00:04:04,940 --> 00:04:06,594 I have enough steel in my starting billet 100 00:04:06,724 --> 00:04:08,726 to be able to get that parameter for length and width. 101 00:04:08,857 --> 00:04:10,728 I am thinking, which are the flattest? 102 00:04:10,859 --> 00:04:13,209 Which are the most similar is size already? 103 00:04:13,340 --> 00:04:15,429 Get rid of all the scale rust, 104 00:04:15,559 --> 00:04:18,127 any type of garbage that will inhibit a weld. 105 00:04:18,258 --> 00:04:19,955 - There's plenty of steel out there 106 00:04:20,085 --> 00:04:22,653 for any of these guys to make an eight- to ten-inch blade. 107 00:04:22,784 --> 00:04:23,915 - But, they're short, fat blades. 108 00:04:24,046 --> 00:04:25,569 They're gonna have to make a good stack 109 00:04:25,700 --> 00:04:27,876 so they can pour it out wide enough. 110 00:04:28,006 --> 00:04:29,704 A base of this blade is about two inches, 111 00:04:29,834 --> 00:04:31,271 two and a quarter inches wide. 112 00:04:31,401 --> 00:04:32,489 - The challenging thing with daggers 113 00:04:32,620 --> 00:04:33,925 is getting them symmetric 114 00:04:34,056 --> 00:04:36,667 and all four faces of the bevel to be even. 115 00:04:36,798 --> 00:04:38,713 That's something I've basically struggled with 116 00:04:38,843 --> 00:04:40,236 when I started making them, 117 00:04:40,367 --> 00:04:42,020 and it's kind of why I stopped making them. 118 00:04:42,151 --> 00:04:44,762 - One of the things that's hard when you start doing daggers 119 00:04:44,893 --> 00:04:47,722 or symmetrical shapes is actually finding that symmetry. 120 00:04:47,852 --> 00:04:50,072 A dagger profile is difficult 121 00:04:50,202 --> 00:04:51,943 and different from a traditional knife, 122 00:04:52,074 --> 00:04:54,685 in that you have to shape four identical sides instead of two 123 00:04:54,816 --> 00:04:58,167 to get that traditional diamond shape of the dagger. 124 00:04:58,298 --> 00:04:59,647 - I've made daggers before, 125 00:04:59,777 --> 00:05:02,824 but this pugo or pahuahua thing, 126 00:05:02,954 --> 00:05:06,654 it's wide, its longer than I normally make. 127 00:05:06,784 --> 00:05:09,134 But you know what, I've never run away from a challenge. 128 00:05:09,265 --> 00:05:10,832 So let's tear it up. 129 00:05:10,962 --> 00:05:13,269 For my stack I want to have nine pieces, or more, 130 00:05:13,400 --> 00:05:15,706 so that way when you do draw this out, 131 00:05:15,837 --> 00:05:17,621 you want to have more metal than you need. 132 00:05:17,752 --> 00:05:19,971 Having more is better than not having enough. 133 00:05:20,102 --> 00:05:21,799 - When you stack a billet, 134 00:05:21,930 --> 00:05:24,149 you want to make sure all of them are the same size. 135 00:05:24,280 --> 00:05:26,891 If there's any that stick out bigger than the other, 136 00:05:27,022 --> 00:05:28,719 you'll get, right at the edge there, 137 00:05:28,850 --> 00:05:31,113 you'll get this cold shut where it rolls over eventually, 138 00:05:31,243 --> 00:05:33,289 and it doesn't make a good weld. 139 00:05:33,420 --> 00:05:34,899 - I am goal oriented. 140 00:05:35,030 --> 00:05:37,075 Goal one is to make it to round two. 141 00:05:37,206 --> 00:05:39,687 Goal two is to get to round three. 142 00:05:39,817 --> 00:05:42,167 Goal three is to be "Forged in Fire" champion. 143 00:05:42,298 --> 00:05:44,039 - I want to make this billet setup 144 00:05:44,169 --> 00:05:45,170 as easy as it can be. 145 00:05:45,301 --> 00:05:47,782 So I grab the straightest, 146 00:05:47,912 --> 00:05:50,393 most square looking weapons that I see. 147 00:05:50,524 --> 00:05:52,569 I grab four of them just to make sure I have enough steel. 148 00:05:52,700 --> 00:05:54,484 My mind's going a mile a minute. 149 00:05:54,615 --> 00:05:56,007 I've never made a dagger before, 150 00:05:56,138 --> 00:05:57,531 and I just got to get the jitters out, 151 00:05:57,661 --> 00:05:59,359 get in my groove, 152 00:05:59,489 --> 00:06:02,971 just making another billet like I do every day. 153 00:06:03,101 --> 00:06:05,365 Right now, I've got my billet welded up. 154 00:06:05,495 --> 00:06:06,714 I've got six separate pieces, 155 00:06:06,844 --> 00:06:08,977 about four inches by an inch wide, 156 00:06:09,107 --> 00:06:10,631 got it tacked up, heating up. 157 00:06:10,761 --> 00:06:12,807 I've still got a few jitters that I got to work out, 158 00:06:12,937 --> 00:06:14,374 but I think once 159 00:06:14,504 --> 00:06:17,681 I've got my billet set, I'm going to be rolling. 160 00:06:17,812 --> 00:06:19,161 - Double edged daggers, I have no problem with. 161 00:06:19,291 --> 00:06:20,815 I've made them. 162 00:06:20,945 --> 00:06:22,773 But the challenge with this weapon 163 00:06:22,904 --> 00:06:24,427 is the weapon has to be symmetrical, 164 00:06:24,558 --> 00:06:25,950 and you can't be off. 165 00:06:26,081 --> 00:06:27,735 The judges will see that, they will know that. 166 00:06:27,865 --> 00:06:29,867 If your measurement's wrong, you can go home. 167 00:06:29,998 --> 00:06:32,000 If you don't do your welds right, you can go home. 168 00:06:32,130 --> 00:06:35,525 I don't want to go home. I want to be number one. 169 00:06:35,656 --> 00:06:38,528 - One of the things I love about challenges like this 170 00:06:38,659 --> 00:06:40,443 is there's plenty of steel out there, 171 00:06:40,574 --> 00:06:41,749 it's just not in the right shape. 172 00:06:41,879 --> 00:06:43,228 - Yeah. 173 00:06:43,359 --> 00:06:45,448 - And it's up to them to take those shapes, 174 00:06:45,579 --> 00:06:48,146 forge all of them together, and make a new shape, 175 00:06:48,277 --> 00:06:51,715 and that material management, that planning, is everything. 176 00:06:51,846 --> 00:06:53,238 - Yeah. 177 00:06:53,369 --> 00:06:56,111 - I hand-hammer to set the welds. 178 00:06:56,241 --> 00:06:59,854 I prefer to do it by hand because I know I'm swinging it 179 00:06:59,984 --> 00:07:02,465 at the right weight, the right speed. 180 00:07:02,596 --> 00:07:04,946 - Kevin, he did start with a nice, uniform stack. 181 00:07:05,076 --> 00:07:07,644 But it looked to me like an inch and a half cube, 182 00:07:07,775 --> 00:07:10,560 a little bit lean on the amount of material for this knife. 183 00:07:10,691 --> 00:07:13,563 - When I know my forge welds are set, 184 00:07:13,694 --> 00:07:16,087 I start drawing the billet out length wise. 185 00:07:16,218 --> 00:07:19,439 I don't want to push out too much metal at one time. 186 00:07:19,569 --> 00:07:21,702 I want to maintain that thickness of the blade 187 00:07:21,832 --> 00:07:24,748 because I know the judges are brutal when they test. 188 00:07:24,879 --> 00:07:27,098 Hot metal! 189 00:07:27,229 --> 00:07:29,405 [bleep], I don't know if I got enough material. 190 00:07:29,536 --> 00:07:32,452 ♪ 191 00:07:32,582 --> 00:07:33,757 - Every time you forge weld, 192 00:07:33,888 --> 00:07:35,542 there's always a chance of failure. 193 00:07:35,672 --> 00:07:38,240 So every time I forge weld, I'm nervous. 194 00:07:38,370 --> 00:07:40,895 My first forge weld is just a nice, 195 00:07:41,025 --> 00:07:43,027 light tap to make sure everything is set. 196 00:07:43,158 --> 00:07:44,942 Then once I know that weld is set, 197 00:07:45,073 --> 00:07:47,815 I can start drawing this billet out. 198 00:07:47,945 --> 00:07:50,121 In this competition I think I have a good advantage 199 00:07:50,252 --> 00:07:52,472 in that, you know, I'm pretty adept at forging. 200 00:07:52,602 --> 00:07:53,864 I've forged probably close to 1,000 knives now 201 00:07:53,995 --> 00:07:55,649 in the past three years. 202 00:07:55,779 --> 00:07:58,260 But you can never stop learning about knives, 203 00:07:58,390 --> 00:08:00,610 and I want to learn until the day I die 204 00:08:00,741 --> 00:08:02,873 and make the best knife I can possibly make every day. 205 00:08:03,004 --> 00:08:07,748 ♪ 206 00:08:07,878 --> 00:08:10,054 - When you're forge welding, it's a repetitive process. 207 00:08:10,185 --> 00:08:13,231 You have to heat, hammer, heat, hammer. 208 00:08:13,362 --> 00:08:15,625 So it becomes one solid piece of metal. 209 00:08:15,756 --> 00:08:17,366 And when you're forge welding, 210 00:08:17,497 --> 00:08:20,456 its hit it as hard as you can, as fast as you can. 211 00:08:20,587 --> 00:08:22,284 - When you come out of the forge 212 00:08:22,414 --> 00:08:26,070 and you can see different colorations in even stacks, 213 00:08:26,201 --> 00:08:27,942 I mean, you know that they're not connected, 214 00:08:28,072 --> 00:08:29,247 it's not a good weld. - Yeah. 215 00:08:29,378 --> 00:08:30,901 - Once I get this forged and set, 216 00:08:31,032 --> 00:08:32,729 then I'll take it to big blue. 217 00:08:32,860 --> 00:08:34,601 The thing I'm most worried about is my welds not taking. 218 00:08:34,731 --> 00:08:36,559 Because if those welds don't take, you don't have a billet. 219 00:08:36,690 --> 00:08:39,257 You don't have a billet, you don't have a knife. 220 00:08:39,388 --> 00:08:41,129 ♪ 221 00:08:41,259 --> 00:08:42,522 - Looking on the inside of the bar, 222 00:08:42,652 --> 00:08:44,001 it looks like it's pretty good. 223 00:08:44,132 --> 00:08:46,743 There's no cracks I can see, there's no delams. 224 00:08:46,874 --> 00:08:48,963 It looks like it's a nice clean, solid weld. 225 00:08:49,093 --> 00:08:52,183 - Pat's billet looks a little bit undersized 226 00:08:52,314 --> 00:08:54,403 when we talk about that eight- to ten-inch blade. 227 00:08:54,534 --> 00:08:56,710 - Yeah. - Plus tang. 228 00:08:56,840 --> 00:08:58,755 - Ultimate end for the steel, I'm looking for something 229 00:08:58,886 --> 00:09:00,931 that is a little bit longer 230 00:09:01,062 --> 00:09:03,281 than the parameters in the initial body. 231 00:09:03,412 --> 00:09:05,022 I can then put any extra material 232 00:09:05,153 --> 00:09:06,676 that becomes a little bit too large for me 233 00:09:06,807 --> 00:09:08,112 to deal with for the blade into the tang, 234 00:09:08,243 --> 00:09:09,549 and it can be removed later. 235 00:09:09,679 --> 00:09:12,334 - Bladesmiths, one hour has elapsed. 236 00:09:12,464 --> 00:09:16,294 You have just two hours remaining to finish your work. 237 00:09:16,425 --> 00:09:18,079 - Whoo! 238 00:09:18,209 --> 00:09:23,127 ♪ 239 00:09:23,258 --> 00:09:25,434 - There goes Mike, working it cold again. 240 00:09:25,565 --> 00:09:27,044 I mean, it's all red. 241 00:09:27,175 --> 00:09:29,003 - I think my forge welds are good. 242 00:09:29,133 --> 00:09:31,614 So now I need to lengthen my steel. 243 00:09:31,745 --> 00:09:33,660 - I think that we're gonna see 244 00:09:33,790 --> 00:09:35,183 some serious problems with those welds. 245 00:09:37,141 --> 00:09:39,230 - But I actually make are good.e - I thins 246 00:09:39,361 --> 00:09:40,710 I turn it on the side... 247 00:09:40,841 --> 00:09:42,669 [bleep]. And it starts to split apart, 248 00:09:42,799 --> 00:09:44,584 and that's not what you want to see. 249 00:09:44,714 --> 00:09:47,891 - When Mike set his first weld, it was really cold. 250 00:09:48,022 --> 00:09:49,850 I mean, it was a dull red, and you really want 251 00:09:49,980 --> 00:09:51,634 a bright whit heat. - Right. 252 00:09:51,765 --> 00:09:56,073 - I'm wasting time having to re-set the forge welds. 253 00:09:56,204 --> 00:09:57,771 That's something you can't afford to do 254 00:09:57,901 --> 00:09:59,555 in a three-hour build. 255 00:09:59,686 --> 00:10:03,559 ♪ 256 00:10:03,690 --> 00:10:05,822 - We are almost 90 minutes 257 00:10:05,953 --> 00:10:08,303 into this first round of competition, 258 00:10:08,433 --> 00:10:11,567 and I see a lot of shapes. 259 00:10:11,698 --> 00:10:13,874 I don't see any pugio shapes out there yet. 260 00:10:14,004 --> 00:10:16,224 - Here's the thing, the pugio exists 261 00:10:16,354 --> 00:10:19,836 in the Roman Empire for 600, 700 years. 262 00:10:19,967 --> 00:10:21,621 So there are a lot of variations. 263 00:10:21,751 --> 00:10:23,753 That wasp waist is on all of them, 264 00:10:23,884 --> 00:10:27,061 but the head tends to vary a bit. 265 00:10:27,191 --> 00:10:28,628 ♪ 266 00:10:28,758 --> 00:10:30,455 - I've got the steel drawn out to a long, 267 00:10:30,586 --> 00:10:32,632 tapered, pointy object. 268 00:10:32,762 --> 00:10:34,416 I've got it thick enough that I should be able hand widen 269 00:10:34,546 --> 00:10:36,070 that blade out to where I need it. 270 00:10:36,200 --> 00:10:38,725 - Pat's blade. Are you guys seeing a pugio? 271 00:10:38,855 --> 00:10:40,291 - I'm not. 272 00:10:40,422 --> 00:10:44,208 - The very long tip from that wasp waist. 273 00:10:44,339 --> 00:10:46,210 - It's a very tall wasp. - Yeah. 274 00:10:46,341 --> 00:10:50,301 - Width wise, a little shy on that. 275 00:10:50,432 --> 00:10:52,564 I'm actually a quarter inch under. 276 00:10:52,695 --> 00:10:54,218 At this point I'd have to add steel 277 00:10:54,349 --> 00:10:55,698 to get more width to the blade, 278 00:10:55,829 --> 00:10:58,005 and I don't think I would have enough time. 279 00:10:58,135 --> 00:11:00,660 I'm just gonna continue on with what I'm doing and squeeze out 280 00:11:00,790 --> 00:11:02,357 enough material on both sides 281 00:11:02,487 --> 00:11:05,795 to make up the difference, and I should be good to go. 282 00:11:05,926 --> 00:11:08,189 - It's looking great. 283 00:11:08,319 --> 00:11:11,235 I'm trying to shape as much as I can with my hammer. 284 00:11:11,366 --> 00:11:12,672 My shape's coming along nicely. 285 00:11:12,802 --> 00:11:14,674 I'm starting to see that pugio-looking thing. 286 00:11:14,804 --> 00:11:16,632 I get the hips into it, 287 00:11:16,763 --> 00:11:19,461 but I don't have enough metal for the tang. 288 00:11:19,591 --> 00:11:21,289 I got this piece from one of my weapons 289 00:11:21,419 --> 00:11:23,030 and I'm gonna weld this on as my tang. 290 00:11:23,160 --> 00:11:25,032 Hot, hot. Son of a-- 291 00:11:25,162 --> 00:11:26,686 - Kevin-- - There you go. 292 00:11:26,816 --> 00:11:29,123 - I think Kevin grabbed some more steel. 293 00:11:29,253 --> 00:11:30,602 - Ah, got me. 294 00:11:30,733 --> 00:11:32,169 - Kevin made a blade shape, 295 00:11:32,300 --> 00:11:35,738 and then welded a tang right at the junction 296 00:11:35,869 --> 00:11:39,742 between tang and blade, and that's a weak spot. 297 00:11:39,873 --> 00:11:41,526 - Right, it's the junction between the business end 298 00:11:41,657 --> 00:11:43,615 and the user end. - Yeah. 299 00:11:43,746 --> 00:11:45,356 - Welding a tang onto this knife 300 00:11:45,487 --> 00:11:47,097 will create a weak spot, 301 00:11:47,228 --> 00:11:48,708 but it's going to meet the parameters. 302 00:11:48,838 --> 00:11:50,361 And, if I make it to round two, 303 00:11:50,492 --> 00:11:52,755 I'll figure out how to reinforce that weak spot. 304 00:11:52,886 --> 00:11:55,715 - I'm watching Alex right now use the horn of the anvil 305 00:11:55,845 --> 00:11:57,629 and a hammer to create that wasp waist. 306 00:11:57,760 --> 00:11:59,501 - Yeah. 307 00:11:59,631 --> 00:12:01,764 - So right now, I just finished forging my blade. 308 00:12:01,895 --> 00:12:02,983 Next, I'm going to get the profile 309 00:12:03,113 --> 00:12:04,767 of the knife on the grinder, 310 00:12:04,898 --> 00:12:07,378 maybe add a little bit of beveling before heat treat. 311 00:12:07,509 --> 00:12:09,380 But I did a lot of it with the forging, 312 00:12:09,511 --> 00:12:11,382 so I shouldn't have too much to do on grinding. 313 00:12:11,513 --> 00:12:14,081 - His profile is spot on. 314 00:12:14,211 --> 00:12:16,039 - It's feeling really good, it's got a nice weight to it. 315 00:12:16,170 --> 00:12:17,998 I think it should do really good in the chop test. 316 00:12:18,128 --> 00:12:19,956 Plenty of strength in the tip for a stab. 317 00:12:20,087 --> 00:12:21,871 So I'm feeling all right. 318 00:12:22,002 --> 00:12:25,353 ♪ 319 00:12:25,483 --> 00:12:27,790 - I don't know the quality of his welds, 320 00:12:27,921 --> 00:12:30,488 but Mike has really been able to draw that metal out, 321 00:12:30,619 --> 00:12:32,447 and he's got a great pugio shape. 322 00:12:32,577 --> 00:12:34,318 - Yeah. - Okay. 323 00:12:34,449 --> 00:12:36,059 - My blade's coming together great. 324 00:12:36,190 --> 00:12:37,757 I think that my point isn't quite as drastic 325 00:12:37,887 --> 00:12:39,628 as some of my competitors, 326 00:12:39,759 --> 00:12:42,544 but I think that mine looks more like the example. 327 00:12:42,674 --> 00:12:45,895 It's ugly, but it's good. 328 00:12:46,026 --> 00:12:47,723 - Bladesmiths! 329 00:12:47,854 --> 00:12:50,465 30 minutes remaining in the round. 330 00:12:50,595 --> 00:12:52,946 - I see that my tang is delaminating at the very end, 331 00:12:53,076 --> 00:12:54,861 but I think I have enough steel to cut off 332 00:12:54,991 --> 00:12:57,733 that delaminated part of the tang. 333 00:12:57,864 --> 00:12:59,779 So my knife's finally ready for heat treat, 334 00:12:59,909 --> 00:13:03,565 and the one thing I do not want to do is overheat this steel. 335 00:13:03,695 --> 00:13:05,045 I just spent so much time forging it. 336 00:13:05,175 --> 00:13:08,048 I want to quench this as perfectly as I can. 337 00:13:08,178 --> 00:13:09,832 So I'm just moving it back and forth to try 338 00:13:09,963 --> 00:13:13,357 and even this heat out. 339 00:13:13,488 --> 00:13:17,144 - Alex did manage to do a period-correct Caesar quench. 340 00:13:17,274 --> 00:13:18,798 - Caesar quench? - Yes. 341 00:13:18,928 --> 00:13:21,496 He stabbed that forge 23 times, moving it in and out, 342 00:13:21,626 --> 00:13:23,280 before he went to the oil. 343 00:13:23,411 --> 00:13:25,326 - My knife's looking pretty straight. 344 00:13:25,456 --> 00:13:28,111 It sounds hard, it looks hard. I'm feeling good. 345 00:13:28,242 --> 00:13:29,460 ♪ 346 00:13:29,591 --> 00:13:31,288 - Well, this is what I've got so far. 347 00:13:31,419 --> 00:13:33,073 I've got to go into the heat treat 348 00:13:33,203 --> 00:13:36,728 and then do a little more finish grinding. 349 00:13:36,859 --> 00:13:39,470 - Kevin just quenched his blade. 350 00:13:39,601 --> 00:13:41,211 - He's file-testing it. 351 00:13:41,342 --> 00:13:43,039 - Yeah. - That was quick. 352 00:13:43,170 --> 00:13:44,649 - That was very fast. 353 00:13:44,780 --> 00:13:47,609 - You've got to be [bleep] kidding me. 354 00:13:47,739 --> 00:13:49,785 Half of it's heat treated, half of it's not. 355 00:13:49,916 --> 00:13:52,092 That is bad news. 356 00:13:52,222 --> 00:13:55,443 On the second heat treat, I bring it up to cherry red, 357 00:13:55,573 --> 00:13:57,271 and I got the same problem again. 358 00:13:57,401 --> 00:14:00,404 - Kevin may be file checking while it's still hot 359 00:14:00,535 --> 00:14:01,797 and thinking it didn't get hard. 360 00:14:01,928 --> 00:14:03,886 So going for another quench, and then another quench. 361 00:14:04,017 --> 00:14:06,062 - Oh, that makes sense. 362 00:14:06,193 --> 00:14:07,977 - I'm starting to feel the pressure. 363 00:14:08,108 --> 00:14:09,936 I know I got to get on that grinder 364 00:14:10,066 --> 00:14:11,894 to start getting this thing cleaned up. 365 00:14:12,025 --> 00:14:13,591 - The tip looks very hot. - Yeah. 366 00:14:13,722 --> 00:14:15,158 - Come on, dude. 367 00:14:15,289 --> 00:14:18,422 ♪ 368 00:14:18,553 --> 00:14:20,424 - Nope. What the hell's going on? 369 00:14:20,555 --> 00:14:21,643 I don't know what I'm doing wrong here. 370 00:14:21,773 --> 00:14:27,518 ♪ 371 00:14:27,649 --> 00:14:29,433 Oh, she's hard now. 372 00:14:29,564 --> 00:14:32,132 Whew. I'm good. I'm good. 373 00:14:32,262 --> 00:14:33,785 ♪ 374 00:14:33,916 --> 00:14:36,963 - Looks like Pat's gonna start his heat-treat process. 375 00:14:37,093 --> 00:14:38,660 - Yeah, he's got it in tang first, 376 00:14:38,790 --> 00:14:40,314 so he's not overheating the tip. 377 00:14:40,444 --> 00:14:41,837 That's good. 378 00:14:41,968 --> 00:14:45,101 ♪ 379 00:14:45,232 --> 00:14:46,886 - Looks good and straight. 380 00:14:47,016 --> 00:14:50,324 I'm gonna take it over to the grinder, finish up my profile. 381 00:14:50,454 --> 00:14:52,935 - I don't know how Pat's going to a grinder. 382 00:14:53,066 --> 00:14:56,634 You can't grind metal onto a blade. 383 00:14:56,765 --> 00:14:59,115 - A very subtle wasp waist. 384 00:14:59,246 --> 00:15:01,291 - Like he's making a metal Christmas tree. 385 00:15:01,422 --> 00:15:04,164 ♪ 386 00:15:04,294 --> 00:15:07,471 - The heat treat/the quench is what hardens your blade 387 00:15:07,602 --> 00:15:10,866 so that when you do chopping or cutting, it'll keep its edge. 388 00:15:10,997 --> 00:15:13,347 So I need it to be fully hardened. 389 00:15:13,477 --> 00:15:14,870 ♪ 390 00:15:15,001 --> 00:15:18,439 Perfect. 391 00:15:18,569 --> 00:15:20,745 - Mike's really bringing it home with his shape, I think. 392 00:15:20,876 --> 00:15:22,660 - Yeah. 393 00:15:22,791 --> 00:15:27,709 ♪ 394 00:15:27,839 --> 00:15:29,015 -Ten seconds! 395 00:15:29,145 --> 00:15:30,581 - Yeah. - Not pretty but-- 396 00:15:30,712 --> 00:15:32,192 - It'll work. 397 00:15:32,322 --> 00:15:37,414 -Five, four, three, two, one. 398 00:15:37,545 --> 00:15:39,025 Bladesmiths, shut down your machines, 399 00:15:39,155 --> 00:15:41,549 drop your tools, stop what you're doing. 400 00:15:41,679 --> 00:15:44,073 This first round of bladesmithing competition 401 00:15:44,204 --> 00:15:45,988 is over. 402 00:15:46,119 --> 00:15:47,076 [applause] - Yeah, boys. 403 00:15:47,207 --> 00:15:48,860 - Whoo! 404 00:15:48,991 --> 00:15:51,733 ♪ 405 00:15:51,863 --> 00:15:53,082 - I feel good about turning my blade in 406 00:15:53,213 --> 00:15:54,214 looking the way it does. 407 00:15:54,344 --> 00:15:56,172 I feel like I've hit the parameters. 408 00:15:56,303 --> 00:15:59,610 I have a good working knife. 409 00:15:59,741 --> 00:16:00,960 - All right, bladesmiths, 410 00:16:01,090 --> 00:16:02,570 in this first round of competition, 411 00:16:02,700 --> 00:16:05,007 we asked you to produce a pugio 412 00:16:05,138 --> 00:16:06,661 between eight and ten inches in length. 413 00:16:06,791 --> 00:16:07,967 Now, the judges want to see 414 00:16:08,097 --> 00:16:09,664 what you've done with yourselves. 415 00:16:09,794 --> 00:16:10,970 Mike, you're up first. 416 00:16:11,100 --> 00:16:13,885 Please present your pugio to the judges. 417 00:16:14,016 --> 00:16:17,019 ♪ 418 00:16:17,150 --> 00:16:20,022 - Well, Mike, the profile is pretty Pugi-esque. 419 00:16:20,153 --> 00:16:22,198 There is a wasp waist here. 420 00:16:22,329 --> 00:16:25,549 There is a nice flair, front and back. 421 00:16:25,680 --> 00:16:28,509 Yeah, it's a good-looking blade. 422 00:16:28,639 --> 00:16:29,901 - All right Kevin, you're up. 423 00:16:30,032 --> 00:16:32,078 Please present your blade to the judges. 424 00:16:32,208 --> 00:16:33,688 ♪ 425 00:16:33,818 --> 00:16:35,429 - I like the fact you've got the waist here, 426 00:16:35,559 --> 00:16:37,387 I like the fact you've got the pronounced shoulders here. 427 00:16:37,518 --> 00:16:38,954 You know, that tip meandering over, 428 00:16:39,085 --> 00:16:42,610 that's hard to get my eyes around that hard lean. 429 00:16:42,740 --> 00:16:46,918 Where you did weld on this added tang, 430 00:16:47,049 --> 00:16:51,053 I can see the top edge of that weld. 431 00:16:51,184 --> 00:16:53,882 You've kind of built in a questionable spot. 432 00:16:54,013 --> 00:16:56,667 So I would do everything you can to reinforce that area 433 00:16:56,798 --> 00:16:58,756 if you move forward. 434 00:16:58,887 --> 00:17:00,584 - Roger that. - Alex, you're up next. 435 00:17:00,715 --> 00:17:03,587 Please present your blade to the judges. 436 00:17:03,718 --> 00:17:05,676 ♪ 437 00:17:05,807 --> 00:17:08,984 - Well, Alex, this is a really good pugio shape. 438 00:17:09,115 --> 00:17:11,465 You captured the essence of the knife very well. 439 00:17:11,595 --> 00:17:13,119 The only thing that gives me pause 440 00:17:13,249 --> 00:17:16,992 is that there's not a lot of tang here. 441 00:17:17,123 --> 00:17:18,733 It's right to the end of my hand. 442 00:17:18,863 --> 00:17:20,822 So, if you're gonna put pommel on it, or anything like that, 443 00:17:20,952 --> 00:17:23,303 it's gonna need to be extended somehow, 444 00:17:23,433 --> 00:17:25,609 but, other than that, well done. 445 00:17:25,740 --> 00:17:26,784 - Thank you. 446 00:17:26,915 --> 00:17:28,525 - Pat... 447 00:17:28,656 --> 00:17:31,354 unfortunately the judges won't be evaluating your work 448 00:17:31,485 --> 00:17:33,835 because your blade failed to meet parameters. 449 00:17:33,965 --> 00:17:35,663 ♪ 450 00:17:35,793 --> 00:17:37,708 It is an inch and seven-eighths at the base 451 00:17:37,839 --> 00:17:40,059 and falls short of our two-inch minimum requirement. 452 00:17:40,189 --> 00:17:41,712 And, for that reason, 453 00:17:41,843 --> 00:17:43,845 I'd like to ask you to please surrender your blade. 454 00:17:43,975 --> 00:17:45,281 ♪ 455 00:17:45,412 --> 00:17:47,283 - A little disappointed, 456 00:17:47,414 --> 00:17:49,416 but I gave it the best try I could for the time I had. 457 00:17:49,546 --> 00:17:52,288 My blade was under parameters on the shoulders. 458 00:17:52,419 --> 00:17:54,029 I even tried to re-widen it, 459 00:17:54,160 --> 00:17:55,596 and when I was doing my final grinding, 460 00:17:55,726 --> 00:17:57,119 I must have just taken a little bit more off the edge 461 00:17:57,250 --> 00:17:58,903 than I really thought. 462 00:17:59,034 --> 00:18:01,036 But I'm planning on making a pugio when I get home 463 00:18:01,167 --> 00:18:02,733 because it bothers me 464 00:18:02,864 --> 00:18:04,953 that I missed the mark on daggers, 465 00:18:05,084 --> 00:18:07,825 and now I'm obsessed with trying to figure out 466 00:18:07,956 --> 00:18:09,218 how to do it the right way. 467 00:18:09,349 --> 00:18:11,873 ♪ 468 00:18:12,003 --> 00:18:14,049 - Bladesmiths, congratulations. 469 00:18:14,180 --> 00:18:15,398 You guys have made it 470 00:18:15,529 --> 00:18:16,921 to the second round of this competition, 471 00:18:17,052 --> 00:18:18,575 and now that those blades have been tempered, 472 00:18:18,706 --> 00:18:19,968 it's time to make them fully funconal pugios 473 00:18:20,099 --> 00:18:21,970 by attaching handles to them 474 00:18:22,101 --> 00:18:24,886 and correcting the deficiencies from the first round. 475 00:18:25,016 --> 00:18:26,583 In addition to a handle, 476 00:18:26,714 --> 00:18:28,281 you must have a medallion in the handle, 477 00:18:28,411 --> 00:18:31,022 you must have a guard, and you must have a pommel. 478 00:18:31,153 --> 00:18:33,024 Failure to do so means immediate dismissal 479 00:18:33,155 --> 00:18:34,591 from this forge with no deliberation. 480 00:18:34,722 --> 00:18:36,506 You'll have just two hours 481 00:18:36,637 --> 00:18:38,334 in which to complete all this work. 482 00:18:38,465 --> 00:18:40,858 After this round, your blades will be tested for strength 483 00:18:40,989 --> 00:18:44,210 and durability in a shield stab and slice 484 00:18:44,340 --> 00:18:47,343 and for edge retention in a rope slice. 485 00:18:47,474 --> 00:18:49,911 Good luck, bladesmiths, your two hours starts now. 486 00:18:50,041 --> 00:18:52,392 ♪ 487 00:18:52,522 --> 00:18:54,916 Okay, so these guys have just two hours 488 00:18:55,046 --> 00:18:57,136 to attach these handles with medallions, 489 00:18:57,266 --> 00:18:59,355 with disk pommels and with guards. 490 00:18:59,486 --> 00:19:01,096 - You know, it's funny, the medallion 491 00:19:01,227 --> 00:19:02,793 is gonna be the weirdest little trip up, 492 00:19:02,924 --> 00:19:04,621 'cause it's either gonna be really easy, 493 00:19:04,752 --> 00:19:05,927 you make one out of sheet, 494 00:19:06,057 --> 00:19:07,276 you stick it on either side and you're done; 495 00:19:07,407 --> 00:19:09,278 or you make a more solid one like the example is. 496 00:19:09,409 --> 00:19:11,237 Now you have some fiddly fitting up 497 00:19:11,367 --> 00:19:13,282 of the handle materials to get it all to sit up right. 498 00:19:13,413 --> 00:19:15,545 - All right. - Yeah. 499 00:19:15,676 --> 00:19:18,722 So, I made it to round two, check. 500 00:19:18,853 --> 00:19:20,507 Now I need to bring the tip 501 00:19:20,637 --> 00:19:22,596 back to the center of the blade. 502 00:19:22,726 --> 00:19:25,338 If I was gonna take out Caesar with a crooked blade, 503 00:19:25,468 --> 00:19:27,992 I'd be the embarrassment of the entire Roman Empire. 504 00:19:28,123 --> 00:19:30,734 So I've got to have a straight blade. 505 00:19:30,865 --> 00:19:35,130 I'm grinding off the one edge of the blade 506 00:19:35,261 --> 00:19:38,786 until that tip slowly moves back to the center. 507 00:19:38,916 --> 00:19:41,267 - I do see a lot of good sparks in there, 508 00:19:41,397 --> 00:19:43,182 so he's really grinding in there. 509 00:19:43,312 --> 00:19:46,141 Hopefully just one side to match the other. 510 00:19:46,272 --> 00:19:48,752 - Oops. 511 00:19:48,883 --> 00:19:50,276 ♪ 512 00:19:50,406 --> 00:19:52,016 - So I'm feeling okay about my blade, 513 00:19:52,147 --> 00:19:54,062 but there's so much handle work to do 514 00:19:54,193 --> 00:19:57,674 that it's just insane trying to do it in two hours. 515 00:19:57,805 --> 00:20:00,329 First thing I'm doing is laying out my handle materials 516 00:20:00,460 --> 00:20:02,766 to see how much tang I need to add on. 517 00:20:02,897 --> 00:20:04,551 - Alex's tang was short, 518 00:20:04,681 --> 00:20:06,596 so he's over there dropping beads like it's Mardi Gras. 519 00:20:06,727 --> 00:20:08,163 - [laughs] 520 00:20:08,294 --> 00:20:10,600 ♪ 521 00:20:10,731 --> 00:20:12,733 - Alex has taken a very hot weld 522 00:20:12,863 --> 00:20:14,517 and quenched that weld in water. 523 00:20:14,648 --> 00:20:15,823 - No! - Oh, yeah. 524 00:20:15,953 --> 00:20:17,477 - I know not to do that. 525 00:20:17,607 --> 00:20:20,262 - Welding something, with the heat at that area, 526 00:20:20,393 --> 00:20:22,482 cooling it off with water is gonna make it hard and brittle, 527 00:20:22,612 --> 00:20:24,919 and they break. 528 00:20:25,049 --> 00:20:26,877 - No, there we go. 529 00:20:27,008 --> 00:20:28,444 I'm so excited to be in round two. 530 00:20:28,575 --> 00:20:31,055 But, uh, I got ten hours of work 531 00:20:31,186 --> 00:20:33,144 I got to do in two hours, I don't know. 532 00:20:33,275 --> 00:20:34,494 There it is. 533 00:20:34,624 --> 00:20:35,886 I need to put a guard on. 534 00:20:36,017 --> 00:20:39,238 I'm going with a thin piece of brass. 535 00:20:39,368 --> 00:20:41,240 - The guard and the pommel, 536 00:20:41,370 --> 00:20:43,067 should it be made out of brass or bronze? 537 00:20:43,198 --> 00:20:45,200 - I think brass or bronze would have been, 538 00:20:45,331 --> 00:20:46,332 uh, would have been correct for the period. 539 00:20:46,462 --> 00:20:47,724 I would probably go with that, 540 00:20:47,855 --> 00:20:49,596 and it's easier to file and fit up. 541 00:20:49,726 --> 00:20:51,250 - All right. 542 00:20:51,380 --> 00:20:52,555 - Not beautiful, but it works. 543 00:20:52,686 --> 00:20:54,905 - Bladesmiths, one hour has elapsed. 544 00:20:55,036 --> 00:20:57,430 You have just one hour remaining to finish your work. 545 00:20:57,560 --> 00:20:58,822 ♪ 546 00:20:58,953 --> 00:21:01,825 - Fixing the tip put me way behind. 547 00:21:01,956 --> 00:21:05,525 The plan is to get a block of brass 548 00:21:05,655 --> 00:21:08,571 and plunge a hole down the middle of it 549 00:21:08,702 --> 00:21:11,966 so that the tang can snugly fit into it to reinforce 550 00:21:12,096 --> 00:21:15,491 that weak weld point when I welded on the tang. 551 00:21:15,622 --> 00:21:17,711 So close, so close. 552 00:21:17,841 --> 00:21:18,886 ♪ 553 00:21:19,016 --> 00:21:21,541 Oh, mother of pearl. 554 00:21:21,671 --> 00:21:23,804 I get the guard somewhat firmly attached, 555 00:21:23,934 --> 00:21:27,242 then I move on to the medallion and the pommel. 556 00:21:27,373 --> 00:21:30,680 I cut off four pieces of this brass round stock, 557 00:21:30,811 --> 00:21:32,421 and I'm gonna use two pieces for my pommel 558 00:21:32,552 --> 00:21:35,032 and two pieces for my medallion. 559 00:21:35,163 --> 00:21:38,035 Sexy is not what I'm going for right now. 560 00:21:38,166 --> 00:21:40,168 But then again, you got this. 561 00:21:40,299 --> 00:21:41,561 - I've got my guard fitted up, 562 00:21:41,691 --> 00:21:43,606 and I'm gonna start building this handle. 563 00:21:43,737 --> 00:21:46,479 I need to get a top piece of wood, the medallion, 564 00:21:46,609 --> 00:21:48,437 bottom piece of wood, and the pommel fitted up 565 00:21:48,568 --> 00:21:50,091 before I can even glue and start grinding. 566 00:21:50,221 --> 00:21:52,572 ♪ 567 00:21:52,702 --> 00:21:54,487 I get these pieces fitted up 568 00:21:54,617 --> 00:21:56,489 and I just really need to get these holes drilled 569 00:21:56,619 --> 00:21:59,013 so I can pin my medallion, lock my handle up, 570 00:21:59,143 --> 00:22:01,929 and then get it ground. 571 00:22:02,059 --> 00:22:04,366 - Okay, that not work. 572 00:22:04,497 --> 00:22:06,325 - Is he drilling all of his layers in one shot or-- 573 00:22:06,455 --> 00:22:07,500 - Yeah. 574 00:22:07,630 --> 00:22:09,066 - I can feel the drill bit 575 00:22:09,197 --> 00:22:11,112 start to move through the steel. 576 00:22:11,242 --> 00:22:12,853 - Alex is working with some really big drill bits. 577 00:22:12,983 --> 00:22:15,159 Hopefully he hasn't thinned out his handle material enough 578 00:22:15,290 --> 00:22:16,552 that it's gonna be weak. 579 00:22:16,683 --> 00:22:18,380 - Right. [soft snap] 580 00:22:19,076 --> 00:22:21,383 all: Ohh! 581 00:22:21,514 --> 00:22:22,732 ♪ 582 00:22:22,863 --> 00:22:24,299 - So I start drilling, 583 00:22:24,430 --> 00:22:27,824 and the tang that I welded on breaks off. 584 00:22:27,955 --> 00:22:29,652 - 30 minutes, bladesmiths! 585 00:22:29,783 --> 00:22:32,307 - Luckily, my epoxy hasn't fully cured yet. 586 00:22:32,438 --> 00:22:34,048 So I pull off that second piece 587 00:22:34,178 --> 00:22:35,658 and rush over to the welder 588 00:22:35,789 --> 00:22:38,139 and try and tack this tang back on. 589 00:22:38,269 --> 00:22:39,749 - It's unfortunate. 590 00:22:39,880 --> 00:22:41,969 Alex did that final weld and then quenched it. 591 00:22:42,099 --> 00:22:45,015 You know, that makes for a really brittle area. 592 00:22:45,146 --> 00:22:47,235 - I'm freaking out that I'm not actually 593 00:22:47,366 --> 00:22:49,106 going to be able to finish a knife. 594 00:22:49,237 --> 00:22:51,413 ♪ 595 00:22:51,544 --> 00:22:53,154 - Are you kidding me? 596 00:22:53,284 --> 00:22:54,677 So as I'm grinding it out, 597 00:22:54,808 --> 00:22:56,723 I find a small hole in my wood handle. 598 00:22:56,853 --> 00:22:58,028 Look at that. 599 00:22:58,159 --> 00:23:01,075 So I fill it with epoxy. 600 00:23:01,205 --> 00:23:03,207 I'm filling the holes, I'm covering the handle. 601 00:23:03,338 --> 00:23:06,820 Whatever it is, it is now an epoxy-handled knife. 602 00:23:06,950 --> 00:23:09,388 - It's dripping epoxy off of it. 603 00:23:09,518 --> 00:23:11,390 It's, like, oozing off the of blade. 604 00:23:11,520 --> 00:23:14,218 - But that's just it, you can't fill a hole with epoxy 605 00:23:14,349 --> 00:23:15,959 and then let it sit sideways. 606 00:23:16,090 --> 00:23:17,613 The epoxy will run out of the hole. 607 00:23:17,744 --> 00:23:19,398 ♪ 608 00:23:19,528 --> 00:23:22,096 - These medallions are killing me. 609 00:23:22,226 --> 00:23:23,924 Time's ticking away. 610 00:23:24,054 --> 00:23:26,405 I still got to throw a handle onto it. 611 00:23:26,535 --> 00:23:29,582 - Kevin's handle is literally just the metal pieces. 612 00:23:29,712 --> 00:23:31,758 - I grab some deer leather 613 00:23:31,888 --> 00:23:33,934 and I start cutting strips of it, 614 00:23:34,064 --> 00:23:35,501 and I just start slapping glue on it. 615 00:23:35,631 --> 00:23:37,024 Stretching it and wrapping it, 616 00:23:37,154 --> 00:23:38,852 stretching it and wrapping it. 617 00:23:38,982 --> 00:23:41,637 - There's a work around, a leather-wrapped tang. 618 00:23:41,768 --> 00:23:43,683 - Because that is genius. 619 00:23:43,813 --> 00:23:45,380 - That's what he did, right there. 620 00:23:45,511 --> 00:23:46,599 - I love it. 621 00:23:46,729 --> 00:23:48,557 - Get an edge on this real fast. 622 00:23:48,688 --> 00:23:50,298 I got five minutes for the glue to set up, 623 00:23:50,429 --> 00:23:52,300 so I start getting on the grinder 624 00:23:52,431 --> 00:23:54,911 to put an edge on this thing. 625 00:23:55,042 --> 00:23:57,914 - Did Mike put any medallions on his handle yet? 626 00:23:58,045 --> 00:24:00,439 - I don't know. 627 00:24:00,569 --> 00:24:01,701 - I need to attach my medallions. 628 00:24:01,831 --> 00:24:03,354 Agh! 629 00:24:03,485 --> 00:24:06,140 I can do this with a larger piece of brass 630 00:24:06,270 --> 00:24:08,751 that I used for the pommel. 631 00:24:08,882 --> 00:24:11,580 As I try and cut it, it doesn't work out. 632 00:24:11,711 --> 00:24:14,061 I have to scrap the idea and do something else. 633 00:24:14,191 --> 00:24:15,497 Let's do it. 634 00:24:15,628 --> 00:24:17,891 I don't have time to make it a perfect replica. 635 00:24:18,021 --> 00:24:19,893 I'm doing what I have to to make it a functional knife 636 00:24:20,023 --> 00:24:21,721 that represents what they want. 637 00:24:21,851 --> 00:24:23,287 ♪ 638 00:24:23,418 --> 00:24:25,681 I find some really big pin stock. 639 00:24:25,812 --> 00:24:28,379 It'll be a smaller medallion. 640 00:24:28,510 --> 00:24:30,686 - The normal construction with the medallion, 641 00:24:30,817 --> 00:24:32,558 sliding it over... - Okay. 642 00:24:32,688 --> 00:24:35,386 - So there's a round medallion in the middle, just like this. 643 00:24:35,517 --> 00:24:38,433 - Okay. - Or you can do a two-piece 644 00:24:38,564 --> 00:24:40,522 construction like this, sandwich it. 645 00:24:40,653 --> 00:24:43,612 As long as visually that medallion exists 646 00:24:43,743 --> 00:24:45,266 as the palm slot. - Yeah. 647 00:24:45,396 --> 00:24:47,921 - It's just a matter of sizing that properly. 648 00:24:48,051 --> 00:24:49,444 ♪ 649 00:24:49,575 --> 00:24:52,708 - Five minutes bladesmiths! 650 00:24:52,839 --> 00:24:55,581 Alex set himself back with this crappy weld 651 00:24:55,711 --> 00:24:57,278 that he dipped into water. 652 00:24:57,408 --> 00:25:00,063 His tang snapped off, he's had to re-weld it back on. 653 00:25:00,194 --> 00:25:02,022 Now he's scrambling 654 00:25:02,152 --> 00:25:04,546 and you can see that he's a little bit flustered. 655 00:25:04,677 --> 00:25:06,766 - I don't even know what to focus on. 656 00:25:06,896 --> 00:25:08,985 I've got to get this handle shaped down 657 00:25:09,116 --> 00:25:11,597 to at least something you can hold, 658 00:25:11,727 --> 00:25:13,381 and I haven't even touched my blade yet. 659 00:25:13,512 --> 00:25:15,296 I have to cut a few corners 660 00:25:15,426 --> 00:25:17,385 and do as much as I possibly can 661 00:25:17,516 --> 00:25:18,560 to try and finish this blade. 662 00:25:18,691 --> 00:25:21,607 - Five, four, three, 663 00:25:21,737 --> 00:25:23,870 two, one. 664 00:25:24,000 --> 00:25:26,133 Bladesmiths, shut down your machines, drop your tools. 665 00:25:26,263 --> 00:25:28,614 This second round of competition is over. 666 00:25:28,744 --> 00:25:29,789 [applause] 667 00:25:29,919 --> 00:25:31,530 ♪ 668 00:25:31,660 --> 00:25:34,707 - Uh, I'm not feeling super great. 669 00:25:34,837 --> 00:25:36,839 I barely have an edge on my knife 670 00:25:36,970 --> 00:25:39,363 and my handle is still super rough, 671 00:25:39,494 --> 00:25:41,583 and that was one of the craziest challenges 672 00:25:41,714 --> 00:25:43,106 I've ever had in knife making. 673 00:25:43,237 --> 00:25:45,456 ♪ 674 00:25:45,587 --> 00:25:47,328 - Bladesmiths, welcome to the strength test. 675 00:25:47,458 --> 00:25:49,896 The old shield stab and chop. 676 00:25:50,026 --> 00:25:51,550 To test the strength and durability of your edges 677 00:25:51,680 --> 00:25:53,334 and points on your pugios, 678 00:25:53,464 --> 00:25:55,423 as well as their overall construction, 679 00:25:55,554 --> 00:25:58,905 I'll be chopping and stabbing mercilessly into these shields. 680 00:25:59,035 --> 00:26:00,907 I don't really care what happens to the shields in this. 681 00:26:01,037 --> 00:26:03,866 I want to see what happens to your tip and edges. 682 00:26:03,997 --> 00:26:05,346 Alex, you're up first. You ready? 683 00:26:05,476 --> 00:26:07,087 - Let's do it. - All right. 684 00:26:07,217 --> 00:26:09,306 ♪ 685 00:26:09,437 --> 00:26:12,179 - I'm super nervous going into testing. 686 00:26:12,309 --> 00:26:14,573 I'm not sure how my tang is going to hold up 687 00:26:14,703 --> 00:26:16,009 after I just re-welded it. 688 00:26:16,139 --> 00:26:17,837 My tip is thin, 689 00:26:17,967 --> 00:26:20,709 so I'm just really hoping that it can hold up. 690 00:26:25,888 --> 00:26:32,808 ♪ 691 00:26:35,202 --> 00:26:42,165 ♪ 692 00:26:44,037 --> 00:26:51,000 ♪ 693 00:26:56,876 --> 00:26:59,966 - Well, Alex, first things first, 694 00:27:00,096 --> 00:27:02,664 you lost about a quarter inch of your tip here. 695 00:27:02,795 --> 00:27:04,231 I'm looking at the grain in there, 696 00:27:04,361 --> 00:27:06,973 and it's not as fine as I'd like to see. 697 00:27:07,103 --> 00:27:08,539 It's probably the overheating 698 00:27:08,670 --> 00:27:10,716 during the normalizations or quenches. 699 00:27:10,846 --> 00:27:13,980 That aside, you left some sharp corners 700 00:27:14,110 --> 00:27:16,417 of the wood right here, where the wood contacts the brass, 701 00:27:16,547 --> 00:27:17,810 and it took a little, 702 00:27:17,940 --> 00:27:20,639 a little nibble out of my thumb right here. 703 00:27:20,769 --> 00:27:24,077 But, in total, it's got a good classic pugio shape 704 00:27:24,207 --> 00:27:27,733 and your edge help up really well. 705 00:27:27,863 --> 00:27:29,430 Kevin? 706 00:27:29,560 --> 00:27:32,781 - Let's rock it man. - All right, let's do it. 707 00:27:32,912 --> 00:27:34,914 ♪ 708 00:27:35,044 --> 00:27:38,091 - I'm a little anxious to see how my knife is gonna perform. 709 00:27:38,221 --> 00:27:39,875 One of two things are gonna happen. 710 00:27:40,006 --> 00:27:41,224 Either that shield's gonna give, 711 00:27:41,355 --> 00:27:44,010 or my blade's gonna snap. 712 00:27:44,140 --> 00:27:46,926 [dramatic music] 713 00:27:47,056 --> 00:27:53,759 ♪ 714 00:27:56,109 --> 00:28:02,942 ♪ 715 00:28:07,860 --> 00:28:09,078 - All right, Kevin. 716 00:28:09,209 --> 00:28:11,733 First things first, the tip came off. 717 00:28:11,864 --> 00:28:14,344 Again, this grain is bigger than I like. 718 00:28:14,475 --> 00:28:16,564 You also lost a piece of your edge right here. 719 00:28:16,695 --> 00:28:18,261 There's a nibble out of it. 720 00:28:18,392 --> 00:28:20,263 We can go to your handle construction here. 721 00:28:20,394 --> 00:28:23,005 - Don't call my baby ugly. - No, sir. 722 00:28:23,136 --> 00:28:25,138 Look, you were under a time crunch. 723 00:28:25,268 --> 00:28:27,967 You chose a method of completing the challenge 724 00:28:28,097 --> 00:28:30,578 in a way that's usable and wieldable. 725 00:28:30,709 --> 00:28:32,754 Well done. - I'm down with it. 726 00:28:32,885 --> 00:28:34,582 - Mike, you're up next. What are you thinking? 727 00:28:34,713 --> 00:28:36,889 - Let's do it. - All right. 728 00:28:37,019 --> 00:28:38,934 ♪ 729 00:28:39,065 --> 00:28:41,067 - I haven't been nervous until right now, 730 00:28:41,197 --> 00:28:42,808 and I'm going crazy. 731 00:28:42,938 --> 00:28:44,026 My competitors both lost their tips. 732 00:28:44,157 --> 00:28:45,506 If I can keep my tip on, 733 00:28:45,636 --> 00:28:46,768 I don't think I'm going to have any problems. 734 00:28:46,899 --> 00:28:47,987 But this is out of my control. 735 00:28:48,117 --> 00:28:49,466 This is in the judge's hands. 736 00:28:49,597 --> 00:28:52,382 [dramatic music] 737 00:28:52,513 --> 00:28:57,648 ♪ 738 00:29:04,046 --> 00:29:07,006 ♪ 739 00:29:07,136 --> 00:29:09,791 - Mike, your blade doesn't have medallions 740 00:29:09,922 --> 00:29:11,750 on either side of that handle, 741 00:29:11,880 --> 00:29:14,883 and it is a critical feature in a pugio. 742 00:29:15,014 --> 00:29:17,277 And therefore, your blade cannot be tested 743 00:29:17,407 --> 00:29:19,453 or measured evenly and fairly with your competitors, 744 00:29:19,583 --> 00:29:21,020 and it doesn't make the cut. 745 00:29:21,150 --> 00:29:22,891 You did a lot of hard work here, my friend, 746 00:29:23,022 --> 00:29:25,285 and it's an unfortunate circumstance. 747 00:29:25,415 --> 00:29:27,461 But at this time, I have to ask you 748 00:29:27,591 --> 00:29:28,854 to please leave The Forge. 749 00:29:28,984 --> 00:29:32,248 - Good job, guys. Good job, guys. 750 00:29:32,379 --> 00:29:33,728 - If you're going to come to this competition, 751 00:29:33,859 --> 00:29:35,817 make sure you pay attention to the parameters. 752 00:29:35,948 --> 00:29:37,688 It's very important. 753 00:29:37,819 --> 00:29:41,040 The smalalst little detail that you miss can get you off. 754 00:29:41,170 --> 00:29:42,955 This was an amazing experience. 755 00:29:43,085 --> 00:29:45,740 I truly believe that if I had my weapon tested, 756 00:29:45,871 --> 00:29:47,742 I would have went through to the finals. 757 00:29:47,873 --> 00:29:49,178 What's next for me is go home, 758 00:29:49,309 --> 00:29:50,789 and I'll probably make another pugio, 759 00:29:50,919 --> 00:29:52,573 and I'm gonna send a picture to the judges and say, 760 00:29:52,703 --> 00:29:54,401 "This is what I made." 761 00:29:54,531 --> 00:29:57,970 ♪ 762 00:29:58,100 --> 00:29:59,449 - Alex, Kevin, congratulations. 763 00:29:59,580 --> 00:30:00,842 You guys are in the third 764 00:30:00,973 --> 00:30:02,713 and final round of this competition, 765 00:30:02,844 --> 00:30:04,977 which means that you're both one step closer to the title 766 00:30:05,107 --> 00:30:07,457 of "Forged in Fire" champion and a check for $10,000. 767 00:30:07,588 --> 00:30:09,982 All you need to do now is go home and re-create 768 00:30:10,112 --> 00:30:12,593 this iconic weapon from history. 769 00:30:12,723 --> 00:30:15,552 ♪ 770 00:30:15,683 --> 00:30:17,250 The spatha. 771 00:30:17,380 --> 00:30:19,774 ♪ 772 00:30:19,905 --> 00:30:21,471 The spatha was a vicious sword 773 00:30:21,602 --> 00:30:23,822 given to infantry during the Roman Empire. 774 00:30:23,952 --> 00:30:25,693 The double-edged weapon was used to inflict 775 00:30:25,824 --> 00:30:27,738 deep slashes and deadly cuts on their enemies 776 00:30:27,869 --> 00:30:29,653 while the tapered tip was effective for thrusting. 777 00:30:29,784 --> 00:30:31,307 In the third and fourth centuries, 778 00:30:31,438 --> 00:30:32,874 some of these Roman soldiers turned sides 779 00:30:33,005 --> 00:30:34,397 and became Barbarians. 780 00:30:34,528 --> 00:30:35,746 They then used the spatha 781 00:30:35,877 --> 00:30:37,444 in wars against the Roman Empire, 782 00:30:37,574 --> 00:30:39,141 and eventually led to its demise. 783 00:30:39,272 --> 00:30:41,187 Ancient Rome continues to be the backdrop 784 00:30:41,317 --> 00:30:43,319 for blockbuster films like "Gladiator," 785 00:30:43,450 --> 00:30:47,367 in which the spatha can be seen wielded in battle. 786 00:30:47,497 --> 00:30:50,370 Gentlemen, your final challenge is to forge a spatha. 787 00:30:50,500 --> 00:30:53,852 Your blades must be between 27 and 29 inches in length. 788 00:30:53,982 --> 00:30:56,419 They must have a medial ridge on both sides of the blade, 789 00:30:56,550 --> 00:30:58,204 and it must be double edged. 790 00:30:58,334 --> 00:31:00,641 It must have a wooden guard, and a disk pommel. 791 00:31:00,771 --> 00:31:02,773 You'll have just four days at your home forges 792 00:31:02,904 --> 00:31:04,514 in which to complete this weapon. 793 00:31:04,645 --> 00:31:07,300 After your judges have thoroughly tested your blades, 794 00:31:07,430 --> 00:31:09,693 they'll declare one of you the "Forged in Fire" champion 795 00:31:09,824 --> 00:31:13,915 who walks out of here with that check for $10,000. 796 00:31:14,046 --> 00:31:16,483 Good luck, bladesmiths. We'll see you in four days. 797 00:31:16,613 --> 00:31:19,007 - Good luck. - Kevin. 798 00:31:19,138 --> 00:31:23,707 ♪ 799 00:31:23,838 --> 00:31:26,232 - So, it's day one in Belleville, West Virginia. 800 00:31:26,362 --> 00:31:28,277 I got a spatha to go make. Let's get crackalackin. 801 00:31:28,408 --> 00:31:30,366 Whoo! 802 00:31:30,497 --> 00:31:32,455 I'm gonna be using 5160. 803 00:31:32,586 --> 00:31:34,109 It's a forgiving medium. 804 00:31:34,240 --> 00:31:35,850 It'll bring some strength to whatever 805 00:31:35,981 --> 00:31:39,027 they're gonna smash, cut, break, kill. 806 00:31:39,158 --> 00:31:42,030 So I'm gonna try big sexy first to bash down 807 00:31:42,161 --> 00:31:44,467 the width of that material to about two-and-a-half 808 00:31:44,598 --> 00:31:46,078 to two-and-a-quarter inches wide. 809 00:31:46,208 --> 00:31:49,559 ♪ 810 00:31:49,690 --> 00:31:51,648 Come on, dang it. Work! 811 00:31:51,779 --> 00:31:53,955 ♪ 812 00:31:54,086 --> 00:31:56,827 Four days isn't enough time to make a spatha. 813 00:31:56,958 --> 00:31:59,961 You don't know what the complications are going to be. 814 00:32:00,092 --> 00:32:01,789 Oh, she's getting there though. 815 00:32:01,920 --> 00:32:03,660 I slowly started drawing it out. 816 00:32:03,791 --> 00:32:05,488 I'm about 35 inches long. 817 00:32:05,619 --> 00:32:06,837 You know, it's just patience, 818 00:32:06,968 --> 00:32:08,578 getting the equipment to work right. 819 00:32:08,709 --> 00:32:10,276 Tomorrow, the pressure will be on 820 00:32:10,406 --> 00:32:12,582 because I gotta get this thing quenched. 821 00:32:12,713 --> 00:32:14,367 If I don't, I'm behind the ball. 822 00:32:14,497 --> 00:32:17,196 Whoo! 823 00:32:17,326 --> 00:32:19,067 ♪ 824 00:32:19,198 --> 00:32:20,808 - Definitely excited to be back home, 825 00:32:20,939 --> 00:32:23,506 back in my shop where I'm nice and comfortable. 826 00:32:23,637 --> 00:32:27,075 I'm gonna do a full Damascus blade 827 00:32:27,206 --> 00:32:29,469 with a little bit of a ladder pattern in it. 828 00:32:29,599 --> 00:32:32,211 I'm really looking forward to going all out 829 00:32:32,341 --> 00:32:35,431 and making something really cool to impress the judges. 830 00:32:35,562 --> 00:32:38,217 First press was just nice and quick and light. 831 00:32:38,347 --> 00:32:39,783 Just push everything together. 832 00:32:39,914 --> 00:32:42,786 This next press will be a little more aggressive. 833 00:32:42,917 --> 00:32:46,616 Probably the most important part of this entire build. 834 00:32:46,747 --> 00:32:48,705 My welds seemed to have stuck pretty well. 835 00:32:48,836 --> 00:32:51,056 I'm going to start drawing this thing out. 836 00:32:51,186 --> 00:32:53,580 ♪ 837 00:32:53,710 --> 00:32:54,885 [bleep]. 838 00:32:55,016 --> 00:32:57,192 I've got one seam that came apart. 839 00:32:57,323 --> 00:33:00,195 I think if I just flux it, get it hot and press it again, 840 00:33:00,326 --> 00:33:01,544 it should be okay. 841 00:33:01,675 --> 00:33:03,677 Let's hope. 842 00:33:03,807 --> 00:33:06,897 This might be a make-or-break moment right here. 843 00:33:07,028 --> 00:33:08,987 I really hope that's the only one, 844 00:33:09,117 --> 00:33:11,337 but deep down I'm petrified that there's 845 00:33:11,467 --> 00:33:12,816 gonna be more of these seams 846 00:33:12,947 --> 00:33:15,428 opening up throughout this billet. 847 00:33:15,558 --> 00:33:16,951 [bleep]. 848 00:33:17,082 --> 00:33:20,302 Right there, I can see it's coming apart. 849 00:33:20,433 --> 00:33:21,956 ♪ 850 00:33:22,087 --> 00:33:23,914 Trying to figure out what I'm gonna do. 851 00:33:24,045 --> 00:33:25,916 ♪ 852 00:33:27,962 --> 00:33:30,138 So I think my best bet 853 00:33:30,269 --> 00:33:32,097 is gonna be to break this billet in half 854 00:33:32,227 --> 00:33:36,362 and salvage as much welded steel as I possibly can, 855 00:33:36,492 --> 00:33:40,931 and I'll just do a generic random pattern Damascus, 856 00:33:41,062 --> 00:33:44,457 but it'll still be a Damascus sword. 857 00:33:44,587 --> 00:33:47,286 Well, the good news is both of those seem really solid. 858 00:33:47,416 --> 00:33:49,810 So at least got something out of today. 859 00:33:49,940 --> 00:33:52,030 ♪ 860 00:33:52,160 --> 00:33:54,249 - Today, I need to get the blade done and quenched. 861 00:33:54,380 --> 00:33:57,035 So I got the shoulders put in. 862 00:33:57,165 --> 00:33:59,472 I have the medial ridge where you can distinctly see 863 00:33:59,602 --> 00:34:01,735 where it's starting to come together. 864 00:34:01,865 --> 00:34:06,479 It's time for the quench. 865 00:34:06,609 --> 00:34:08,307 Oh [bleep]. 866 00:34:08,437 --> 00:34:10,961 ♪ 867 00:34:11,092 --> 00:34:13,964 Yeah, look at that [bleep] bend. 868 00:34:14,095 --> 00:34:16,141 We're quenching again 'cause I don't have time 869 00:34:16,271 --> 00:34:18,665 to eff around with a normalization, 870 00:34:18,795 --> 00:34:20,406 'cause I went all the way down to the bottom 871 00:34:20,536 --> 00:34:22,190 and I felt it bend. 872 00:34:22,321 --> 00:34:25,367 I got to go through all the steps all over again. 873 00:34:25,498 --> 00:34:29,458 ♪ 874 00:34:29,589 --> 00:34:31,591 Still got that bend. 875 00:34:31,721 --> 00:34:34,507 I'm going to temper overnight, and in that process, 876 00:34:34,637 --> 00:34:37,901 it'll start to hopefully normalize down. 877 00:34:38,032 --> 00:34:38,989 It's hit or miss. 878 00:34:39,120 --> 00:34:40,252 It's either going to go well, 879 00:34:40,382 --> 00:34:41,688 or it's gonna go wrong, 880 00:34:41,818 --> 00:34:44,473 and yeah, it went wrong today. 881 00:34:44,604 --> 00:34:46,475 ♪ 882 00:34:46,606 --> 00:34:48,216 - It's the morning of day two. 883 00:34:48,347 --> 00:34:50,088 I definitely had some setbacks yesterday. 884 00:34:50,218 --> 00:34:52,090 Starting the day with my billet tacked up 885 00:34:52,220 --> 00:34:53,917 and ready for forge welding. 886 00:34:54,048 --> 00:34:55,180 And I'm hoping to end the day 887 00:34:55,310 --> 00:34:57,225 with a quenched and hardened spatha. 888 00:34:57,356 --> 00:34:59,184 First press. 889 00:34:59,314 --> 00:35:02,143 ♪ 890 00:35:02,274 --> 00:35:06,452 Looks okay so far, but I'm still gonna be really careful. 891 00:35:06,582 --> 00:35:10,195 I've got my billet drawn out pretty close to shape. 892 00:35:10,325 --> 00:35:12,371 I have just enough length here, 893 00:35:12,501 --> 00:35:14,721 and you can see I'm kind of forging in 894 00:35:14,851 --> 00:35:16,940 that medial ridge already. 895 00:35:17,071 --> 00:35:18,942 This is the longest blade 896 00:35:19,073 --> 00:35:20,727 I have ever attempted to quench. 897 00:35:20,857 --> 00:35:22,685 ♪ 898 00:35:22,816 --> 00:35:24,774 I pull the blade out of the oil. 899 00:35:24,905 --> 00:35:26,036 At the end of the day, 900 00:35:26,167 --> 00:35:27,647 I have an intact Damascus blade. 901 00:35:27,777 --> 00:35:29,431 So first thing tomorrow, I'm gonna get my blade etched 902 00:35:29,562 --> 00:35:31,433 and the handle prepared, 903 00:35:31,564 --> 00:35:33,522 and I'm looking forward to a good day. 904 00:35:33,653 --> 00:35:35,394 ♪ 905 00:35:35,524 --> 00:35:37,657 - I'm feeling better than last night 906 00:35:37,787 --> 00:35:39,006 because I got the blade tempered 907 00:35:39,137 --> 00:35:40,355 and got it straight. 908 00:35:40,486 --> 00:35:41,965 Still behind the ball. 909 00:35:42,096 --> 00:35:44,664 I'm gonna start to fit up the handle. 910 00:35:44,794 --> 00:35:46,361 Start looking at different parts 911 00:35:46,492 --> 00:35:48,146 and what I think looks well. 912 00:35:48,276 --> 00:35:50,452 So my design plan for this pommel 913 00:35:50,583 --> 00:35:52,628 is I'm going to take the two ends of the deer antlers 914 00:35:52,759 --> 00:35:55,588 and I'm going to carve a lion's head out of them. 915 00:35:55,718 --> 00:35:58,591 Hand-carving anything is time consuming, 916 00:35:58,721 --> 00:36:00,810 so I can't get lost in my head. 917 00:36:00,941 --> 00:36:03,465 I'll set it in on top of glow-in-the-dark resin, 918 00:36:03,596 --> 00:36:05,641 and then I'll fill that in with a clear epoxy. 919 00:36:05,772 --> 00:36:07,948 I'm not walking in there with something plain. 920 00:36:08,078 --> 00:36:09,558 Tomorrow I'm going to put 921 00:36:09,689 --> 00:36:11,430 some bronze metal stain on the blade, 922 00:36:11,560 --> 00:36:12,953 and I'm going to finish this no matter what. 923 00:36:13,083 --> 00:36:14,737 It'll be done. 924 00:36:14,868 --> 00:36:16,043 ♪ 925 00:36:16,174 --> 00:36:17,305 - I started day four. 926 00:36:17,436 --> 00:36:18,611 The fatigue of the past couple of days 927 00:36:18,741 --> 00:36:20,178 is definitely starting to set in. 928 00:36:20,308 --> 00:36:22,136 The blades been etched in the coffee overnight 929 00:36:22,267 --> 00:36:24,138 to really bring out the contrast. 930 00:36:24,269 --> 00:36:27,315 Yeah, it really darkened up that 1084. 931 00:36:27,446 --> 00:36:30,013 So the spatha needs to have a wooden guard 932 00:36:30,144 --> 00:36:31,798 and a disk-shaped pommel. 933 00:36:31,928 --> 00:36:34,279 So, I'm going to do a stacked handle. 934 00:36:34,409 --> 00:36:36,672 I'm using iron wood for the guard and the pommel 935 00:36:36,803 --> 00:36:38,413 because it's super strong, 936 00:36:38,544 --> 00:36:39,806 and then I'm gonna use black wood 937 00:36:39,936 --> 00:36:41,677 for the main part of the handle. 938 00:36:41,808 --> 00:36:44,419 I've got all my individual pieces of this handle 939 00:36:44,550 --> 00:36:46,639 fitted up nice and tight. 940 00:36:46,769 --> 00:36:48,380 I gotta get this blade sharpened, 941 00:36:48,510 --> 00:36:50,208 and I've never sharpened anything this long before. 942 00:36:50,338 --> 00:36:52,384 But I know how to put an edge on a knife. 943 00:36:52,514 --> 00:36:54,777 I cannot wait to see this thing put to the test. 944 00:36:54,908 --> 00:36:59,913 ♪ 945 00:37:00,043 --> 00:37:01,001 Word. 946 00:37:01,131 --> 00:37:03,960 [dramatic music] 947 00:37:04,091 --> 00:37:06,224 ♪ 948 00:37:06,354 --> 00:37:08,269 - Bladesmiths, welcome back to The Forge. 949 00:37:08,400 --> 00:37:10,489 You fellas have had four days at your home forges 950 00:37:10,619 --> 00:37:12,752 to work on your finale spathas. 951 00:37:12,882 --> 00:37:14,667 Alex, how did it go? 952 00:37:14,797 --> 00:37:17,104 - I definitely managed to find my fair share of challenges, 953 00:37:17,235 --> 00:37:18,497 but it went pretty well. 954 00:37:18,627 --> 00:37:20,281 ♪ 955 00:37:20,412 --> 00:37:22,544 My blade is about a 50-layer 956 00:37:22,675 --> 00:37:25,765 Damascus steel out of SK5 and 15N20, 957 00:37:25,895 --> 00:37:29,203 with a wrought iron guard and pommel inset, 958 00:37:29,334 --> 00:37:31,249 and I've got iron wood guard and pommel 959 00:37:31,379 --> 00:37:33,251 with a black wood handle. 960 00:37:33,381 --> 00:37:35,862 - Kevin, tell us a little bit about your blade. 961 00:37:35,992 --> 00:37:38,081 - I made a blade out of 5160, 962 00:37:38,212 --> 00:37:39,866 and I made a pommel 963 00:37:39,996 --> 00:37:41,955 out of brass sandwiched with rosewood, 964 00:37:42,085 --> 00:37:45,088 and then I used tagua nuts to make it look like ivory, 965 00:37:45,219 --> 00:37:48,135 and then bronze stained the sword itself. 966 00:37:48,266 --> 00:37:50,050 - Nice, that's why it's got that red appearance. 967 00:37:50,180 --> 00:37:51,747 - It does. 968 00:37:51,878 --> 00:37:53,358 - All right, to determine which one of you 969 00:37:53,488 --> 00:37:54,663 is our next "Forged in Fire" champion, 970 00:37:54,794 --> 00:37:57,100 we will put your blades through three tests. 971 00:37:57,231 --> 00:37:58,537 There will be a strength test, a sharpness test, 972 00:37:58,667 --> 00:38:00,452 and up first, the KEAL test. 973 00:38:00,582 --> 00:38:02,236 Doug. 974 00:38:02,367 --> 00:38:05,108 ♪ 975 00:38:05,239 --> 00:38:06,414 - All right, bladesmiths, 976 00:38:06,545 --> 00:38:08,764 your spatha swords look amazing. 977 00:38:08,895 --> 00:38:11,506 It's time to find out what kind of lethal damage they can do. 978 00:38:11,637 --> 00:38:13,378 To do that, I will take your weapon, 979 00:38:13,508 --> 00:38:15,423 deliver some killing slashes and blows 980 00:38:15,554 --> 00:38:18,905 on this more than willing ballistics dummy. 981 00:38:19,035 --> 00:38:20,341 Alex, you're up first. You ready for this? 982 00:38:20,472 --> 00:38:23,344 - Let's do it. - Let's do it. 983 00:38:23,475 --> 00:38:25,259 - As soon as I finished this blade, 984 00:38:25,390 --> 00:38:27,392 I was content knowing whatever's gonna happen 985 00:38:27,522 --> 00:38:30,046 is gonna happen, but now that I'm here, 986 00:38:30,177 --> 00:38:32,353 standing in front of the dummy and Doug's got my sword, 987 00:38:32,484 --> 00:38:33,354 I'm starting to get a little jittery. 988 00:38:36,096 --> 00:38:38,577 Yeah, I'm a little nervous to see what this blade does. 989 00:38:38,707 --> 00:38:42,450 [exhales] 990 00:38:42,581 --> 00:38:45,410 [dramatic music] 991 00:38:45,540 --> 00:38:52,417 ♪ 992 00:38:56,377 --> 00:39:03,253 ♪ 993 00:39:10,565 --> 00:39:12,088 [chuckles] 994 00:39:12,219 --> 00:39:13,699 ♪ 995 00:39:13,829 --> 00:39:16,266 - All right, Alex, first up, 996 00:39:16,397 --> 00:39:18,094 I can really appreciate the beauty 997 00:39:18,225 --> 00:39:20,009 that you have with your Damascus pattern right there. 998 00:39:20,140 --> 00:39:21,881 It's really stands out. 999 00:39:22,011 --> 00:39:24,187 Very clean lines. 1000 00:39:24,318 --> 00:39:26,842 The medial ridge you have on here, I can imagine, 1001 00:39:26,973 --> 00:39:28,714 well, how much work that takes to get it 1002 00:39:28,844 --> 00:39:32,674 almost perfectly straight all the way through to the tip. 1003 00:39:32,805 --> 00:39:35,634 Your tip is sharp enough to penetrate with a thrust 1004 00:39:35,764 --> 00:39:37,375 and lacerate on the way out. 1005 00:39:37,505 --> 00:39:39,377 And most importantly, 1006 00:39:39,507 --> 00:39:40,726 it will KEAL. 1007 00:39:40,856 --> 00:39:42,858 - Thank you. - Good job. 1008 00:39:42,989 --> 00:39:44,382 All right, Kevin, it's your turn. So you ready? 1009 00:39:44,512 --> 00:39:47,646 - Hell yeah. - Let's do this. 1010 00:39:47,776 --> 00:39:51,084 - Alex's spatha just destroyed that ballistics dummy. 1011 00:39:51,214 --> 00:39:54,304 And now I'm feeling anxious, excited. 1012 00:39:54,435 --> 00:39:56,698 I got the adrenaline going. 1013 00:39:56,829 --> 00:39:59,658 [tense music] 1014 00:39:59,788 --> 00:40:06,882 ♪ 1015 00:40:07,013 --> 00:40:08,667 - It doesn't have a ridge. - Through to the tip. 1016 00:40:08,797 --> 00:40:11,060 ♪ 1017 00:40:11,191 --> 00:40:12,975 No medial ridge on either side of the blade. 1018 00:40:13,106 --> 00:40:15,325 It's one of the parameters. - Right. 1019 00:40:15,456 --> 00:40:17,980 ♪ 1020 00:40:18,111 --> 00:40:20,418 - [sighs] 1021 00:40:20,548 --> 00:40:23,377 Kevin, your blade must fall within our parameters 1022 00:40:23,508 --> 00:40:25,945 in order to be tested evenly and fairly 1023 00:40:26,075 --> 00:40:27,512 with your competitors. 1024 00:40:27,642 --> 00:40:30,166 Your blade does not have a central ridge. 1025 00:40:30,297 --> 00:40:31,994 That was a parameter that was outlined 1026 00:40:32,125 --> 00:40:33,387 before we ever sent you home. 1027 00:40:33,518 --> 00:40:34,867 And for that reason, 1028 00:40:34,997 --> 00:40:37,043 you cannot be the "Forged in Fire" champion. 1029 00:40:37,173 --> 00:40:38,827 Come on, my friend. 1030 00:40:38,958 --> 00:40:41,482 - You know, it's just a bummer I can't see it tested. 1031 00:40:41,613 --> 00:40:44,354 That's what I really wanted. I want to see how it holds up. 1032 00:40:44,485 --> 00:40:45,617 - Nice work on that handle, though. 1033 00:40:45,747 --> 00:40:47,270 - Thank you, I appreciate it. 1034 00:40:47,401 --> 00:40:50,752 When I was making it, it had the defined ridge in it. 1035 00:40:50,883 --> 00:40:52,798 Just with the sanding and grinding, 1036 00:40:52,928 --> 00:40:54,408 it just took more of it off. 1037 00:40:54,539 --> 00:40:56,366 But this whole experience has been a blast. 1038 00:40:56,497 --> 00:40:57,933 Congratulations. 1039 00:40:58,064 --> 00:40:59,457 This isn't a loss. 1040 00:40:59,587 --> 00:41:02,024 I'm coming home with a $10,000 experience. 1041 00:41:02,155 --> 00:41:03,939 ♪ 1042 00:41:04,070 --> 00:41:07,508 - Alex, you made a sharp and deadly spatha. 1043 00:41:07,639 --> 00:41:09,205 But not only that, you made something 1044 00:41:09,336 --> 00:41:11,860 that is detailed and beautiful. 1045 00:41:11,991 --> 00:41:14,994 Your attention to detail has elevated you 1046 00:41:15,124 --> 00:41:17,257 to the title of "Forged in Fire" champion. 1047 00:41:17,387 --> 00:41:18,737 Congratulations. 1048 00:41:18,867 --> 00:41:21,783 Your title comes with a check for $10,000. 1049 00:41:21,914 --> 00:41:23,176 Good job, brother. 1050 00:41:23,306 --> 00:41:24,569 - This is pretty wild. 1051 00:41:24,699 --> 00:41:26,484 I came here to challenge myself 1052 00:41:26,614 --> 00:41:28,747 and put myself through a super rigorous test 1053 00:41:28,877 --> 00:41:30,618 and I came out on top, and it feels great. 1054 00:41:30,749 --> 00:41:32,707 This $10,000, 1055 00:41:32,838 --> 00:41:35,405 I'm actually gonna give it all straight to my parents. 1056 00:41:35,536 --> 00:41:37,407 They supported me through college 1057 00:41:37,538 --> 00:41:38,887 as I was learning bladesmithing 1058 00:41:39,018 --> 00:41:40,498 and they're both getting ready to retire. 1059 00:41:40,628 --> 00:41:42,804 So it's all going to them. 1060 00:41:42,935 --> 00:41:48,897 ♪