1 00:00:05,006 --> 00:00:07,798 [dramatic music] 2 00:00:07,883 --> 00:00:10,259 ♪ ♪ 3 00:00:10,344 --> 00:00:13,721 [rock music] 4 00:00:13,806 --> 00:00:15,973 - my name is kyle farace. I'm 34 years old. 5 00:00:16,058 --> 00:00:19,977 I met my wife about a year and a half ago, 6 00:00:20,062 --> 00:00:22,354 and she introduced me to bladesmithing. 7 00:00:22,398 --> 00:00:24,815 We actually forged our own wedding rings. 8 00:00:24,900 --> 00:00:27,026 ♪ ♪ 9 00:00:27,069 --> 00:00:28,652 - my name is zach tarbell. 10 00:00:28,738 --> 00:00:30,320 I'm 27 years old, 11 00:00:30,364 --> 00:00:32,031 I'm from rochester, new york. 12 00:00:32,116 --> 00:00:35,617 I'm a welding instructor and a part-time bladesmith. 13 00:00:35,703 --> 00:00:36,952 I'm ready to go to work, 14 00:00:37,038 --> 00:00:38,829 and I'm looking for a challenge. 15 00:00:38,914 --> 00:00:41,707 - My name is ben allanson, and I'm 34 years old. 16 00:00:41,792 --> 00:00:44,126 I've been bladesmithing about eight years now. 17 00:00:44,211 --> 00:00:47,004 I have a ton of people rooting for me back home-- 18 00:00:47,089 --> 00:00:49,465 my wife and our four beautiful boys. 19 00:00:49,550 --> 00:00:51,550 And I just want to say my four beautiful boys are dogs. 20 00:00:51,594 --> 00:00:53,302 They're not people. 21 00:00:53,387 --> 00:00:56,722 - My name is aj saracinello. I'm 31 years old. 22 00:00:56,807 --> 00:00:59,183 I'm from totowa, new jersey, and I've been bladesmithing 23 00:00:59,268 --> 00:01:01,101 as a hobby for about eight years. 24 00:01:01,187 --> 00:01:03,228 When I tell people that I make knives, 25 00:01:03,272 --> 00:01:04,855 some people find it pretty interesting, 26 00:01:04,940 --> 00:01:06,565 and other people kind of look like, 27 00:01:06,609 --> 00:01:08,734 "ah, maybe we're not gonna be friends with this dude." 28 00:01:08,778 --> 00:01:10,444 [chuckles] 29 00:01:10,529 --> 00:01:12,946 - bladesmiths, welcome to the forge. 30 00:01:13,032 --> 00:01:15,365 You're about to take part in three rounds 31 00:01:15,451 --> 00:01:17,701 of intense forging competition. 32 00:01:17,787 --> 00:01:20,245 At the end of each round, you're gonna present your work 33 00:01:20,289 --> 00:01:21,705 to our panel of specialists. 34 00:01:21,791 --> 00:01:23,415 The judges for this competition are gonna be 35 00:01:23,501 --> 00:01:25,084 two-time "forged in fire" champion 36 00:01:25,169 --> 00:01:26,710 ben abbott, 37 00:01:26,796 --> 00:01:29,046 historic-weapons re-creation specialist 38 00:01:29,131 --> 00:01:30,714 dave baker, 39 00:01:30,800 --> 00:01:32,174 and edged-weapon specialist 40 00:01:32,259 --> 00:01:33,509 and kali martial artist 41 00:01:33,594 --> 00:01:34,968 doug marcaida. 42 00:01:35,054 --> 00:01:36,386 ♪ ♪ 43 00:01:36,472 --> 00:01:38,639 now, remember, there's $10,000 and the title 44 00:01:38,724 --> 00:01:40,724 of "forged in fire" champion on the line. 45 00:01:40,810 --> 00:01:41,934 Today in the forge, 46 00:01:42,019 --> 00:01:43,393 we feel like doing a little experimenting. 47 00:01:43,479 --> 00:01:44,728 ♪ ♪ 48 00:01:44,772 --> 00:01:45,854 in round one of the challenge, 49 00:01:45,940 --> 00:01:47,272 we're gonna ask you to make blades 50 00:01:47,358 --> 00:01:48,982 using canister damascus. 51 00:01:49,068 --> 00:01:50,025 ♪ ♪ 52 00:01:50,111 --> 00:01:51,151 but if you look around, 53 00:01:51,237 --> 00:01:53,821 you notice there's no cannisters. 54 00:01:53,906 --> 00:01:56,323 That's because we're gonna ask you to use these... 55 00:01:56,408 --> 00:01:58,575 ♪ ♪ 56 00:01:58,661 --> 00:02:00,410 round tubes. 57 00:02:00,496 --> 00:02:01,411 ♪ ♪ 58 00:02:01,497 --> 00:02:03,080 we're calling this challenge 59 00:02:03,165 --> 00:02:04,248 tubular cannister. 60 00:02:04,333 --> 00:02:05,374 ♪ ♪ 61 00:02:05,459 --> 00:02:07,251 - I've made cannister a few times 62 00:02:07,294 --> 00:02:09,294 but always with a square tube. 63 00:02:09,338 --> 00:02:11,296 You don't make cannister with round tube. 64 00:02:11,382 --> 00:02:13,882 - Now, we know this is far from a traditional technique, 65 00:02:13,968 --> 00:02:15,843 so you're gonna have to figure out your workarounds 66 00:02:15,928 --> 00:02:17,302 and make it work. 67 00:02:17,388 --> 00:02:19,012 Now, let's talk steel. 68 00:02:19,098 --> 00:02:23,475 ♪ ♪ 69 00:02:23,561 --> 00:02:25,727 you each have a bucket of high-carbon steel 70 00:02:25,813 --> 00:02:26,895 in front of you. 71 00:02:26,981 --> 00:02:29,189 We want you to use every last ounce of it 72 00:02:29,275 --> 00:02:31,441 in your two-inch tubular cannister. 73 00:02:31,527 --> 00:02:33,569 Nothing can be wasted. - I knew it. 74 00:02:33,654 --> 00:02:35,237 I knew there was gonna be some-- 75 00:02:35,322 --> 00:02:38,115 there's a ball bearing that's just a little bit too large 76 00:02:38,200 --> 00:02:39,825 to fit down that pipe. 77 00:02:39,910 --> 00:02:41,618 Man, how do I get it in there? 78 00:02:41,704 --> 00:02:43,245 ♪ ♪ 79 00:02:43,330 --> 00:02:45,205 - and your blades need to follow these parameters... 80 00:02:45,291 --> 00:02:47,583 We want you to make your signature blade 81 00:02:47,668 --> 00:02:49,001 in your signature style. 82 00:02:49,086 --> 00:02:51,003 Your blades need to be set up for a through 83 00:02:51,046 --> 00:02:54,173 or a hidden tang and between 14 and 16 inches 84 00:02:54,216 --> 00:02:55,632 from tip to plunge grind. 85 00:02:55,718 --> 00:02:57,134 Now, in round two of the competition, 86 00:02:57,219 --> 00:02:58,635 you'll be adding handles to your blades, 87 00:02:58,721 --> 00:03:00,220 making them fully functional weapons. 88 00:03:00,306 --> 00:03:02,514 At that point, we'll be testing for strength and durability 89 00:03:02,558 --> 00:03:04,683 in the steel wind chime chop 90 00:03:04,768 --> 00:03:07,603 and for edge retention in a rubber tube slice. 91 00:03:07,688 --> 00:03:09,855 Bladesmiths, you've got three hours to complete your work. 92 00:03:09,940 --> 00:03:12,774 Good luck. Your time starts now. 93 00:03:12,860 --> 00:03:14,443 [rock music] 94 00:03:14,528 --> 00:03:16,737 - we are off to the races! 95 00:03:16,822 --> 00:03:18,822 ♪ ♪ 96 00:03:18,908 --> 00:03:20,490 - so a normal cannister damascus 97 00:03:20,534 --> 00:03:23,327 is made with a 2-by-2 square cannister. 98 00:03:23,412 --> 00:03:25,037 What makes this more difficult? 99 00:03:25,122 --> 00:03:27,164 - The biggest challenge that they're running into 100 00:03:27,249 --> 00:03:29,208 is that the large ball doesn't fit inside the cannister. 101 00:03:29,293 --> 00:03:32,502 - None of the parts other than the small ball bearings fit in. 102 00:03:32,588 --> 00:03:34,671 So they've all got to be either 103 00:03:34,757 --> 00:03:37,591 cut down or crushed. 104 00:03:37,676 --> 00:03:39,927 - I've never done a tube damascus before. 105 00:03:40,012 --> 00:03:41,887 So I'm just trying to think in my head 106 00:03:41,972 --> 00:03:44,848 how I'm gonna figure this out to get a good forge weld. 107 00:03:44,934 --> 00:03:48,143 I immediately started thinking about my checklist 108 00:03:48,229 --> 00:03:49,895 and starting step one. 109 00:03:49,980 --> 00:03:52,397 Make my cannister, clean up all the material... 110 00:03:52,483 --> 00:03:54,233 Oh, that's long. 111 00:03:54,276 --> 00:03:56,944 So I don't get sidetracked. 112 00:03:57,029 --> 00:03:59,696 It takes a while to cut a ball bearing. 113 00:03:59,782 --> 00:04:01,823 So I'm thinking it would be quicker 114 00:04:01,909 --> 00:04:03,533 to draw it out 115 00:04:03,619 --> 00:04:07,329 and then just pretty much throw the whole thing in a cannister. 116 00:04:07,414 --> 00:04:08,705 ♪ wee-ooh ♪ 117 00:04:08,791 --> 00:04:10,791 - [humming] 118 00:04:10,876 --> 00:04:12,209 my plan for the cannister 119 00:04:12,294 --> 00:04:14,586 is to cut off six inches, 120 00:04:14,672 --> 00:04:16,588 which is gonna be easier to manage 121 00:04:16,632 --> 00:04:18,799 in and out of the forge and on the power hammer. 122 00:04:18,884 --> 00:04:21,718 - You can do a volume calculation 123 00:04:21,804 --> 00:04:24,012 figuring out how much tube you need. 124 00:04:24,098 --> 00:04:27,391 I'd leave at least a 1/2 inch of materials 125 00:04:27,476 --> 00:04:30,227 on either side of what I wanted 126 00:04:30,312 --> 00:04:33,063 so I've got sacrificial material to get rid of. 127 00:04:33,148 --> 00:04:34,273 ♪ ♪ 128 00:04:34,358 --> 00:04:36,149 - at the chop saw, I realize 129 00:04:36,235 --> 00:04:37,693 that it's probably a little bit too short, 130 00:04:37,778 --> 00:04:40,320 but at this point, I'm gonna see what happens. 131 00:04:40,406 --> 00:04:43,031 - It's always fun when you're more than 20 minutes in 132 00:04:43,117 --> 00:04:44,658 and nobody's working on a knife yet. 133 00:04:44,743 --> 00:04:47,953 - A round cannister is an unknown to me. 134 00:04:48,038 --> 00:04:50,038 I don't know how it's gonna behave. 135 00:04:50,124 --> 00:04:52,124 I'm used to square tube. 136 00:04:52,209 --> 00:04:54,543 So I decide to start with something 137 00:04:54,628 --> 00:04:55,919 that I'm familiar with. 138 00:04:56,005 --> 00:04:57,921 - Zach squared up his pipe. 139 00:04:58,007 --> 00:05:00,215 We always use squaring dies, 140 00:05:00,301 --> 00:05:02,050 to try to apply force 141 00:05:02,136 --> 00:05:04,052 equally on all four faces, 142 00:05:04,138 --> 00:05:06,096 to compress to the center, 143 00:05:06,181 --> 00:05:07,931 and we don't have any rounding dies. 144 00:05:08,017 --> 00:05:10,600 ♪ ♪ 145 00:05:10,686 --> 00:05:12,602 - I got all these materials in front of me. 146 00:05:12,688 --> 00:05:14,813 I'm gonna break them down as small as I can 147 00:05:14,898 --> 00:05:16,815 to fit them into that cannister. 148 00:05:16,900 --> 00:05:19,735 I get the big ball bearing broken down into thirds, 149 00:05:19,820 --> 00:05:21,069 but it's still not fitting. 150 00:05:21,155 --> 00:05:22,487 [bleep]. 151 00:05:22,531 --> 00:05:24,323 So I've got to take more pieces off of it. 152 00:05:24,366 --> 00:05:25,782 - It's hard enough thinking, 153 00:05:25,868 --> 00:05:28,327 "how do I make a knife in three hours?" 154 00:05:28,412 --> 00:05:30,454 now they have to think outside of the box 155 00:05:30,539 --> 00:05:32,456 or, in this case, outside of the tube. 156 00:05:32,541 --> 00:05:34,291 [laughter] 157 00:05:34,376 --> 00:05:37,336 - the one time I tried cannister damascus, 158 00:05:37,421 --> 00:05:39,629 it failed miserably, 159 00:05:39,673 --> 00:05:41,381 and that was with square can. 160 00:05:41,467 --> 00:05:43,550 ♪ ♪ 161 00:05:43,635 --> 00:05:46,386 I cut my cannister down to about six inches 162 00:05:46,472 --> 00:05:48,555 'cause I know I don't want to be dealing 163 00:05:48,640 --> 00:05:50,891 with an extensive amount of steel 164 00:05:50,976 --> 00:05:52,934 to try and forge this blade. 165 00:05:53,020 --> 00:05:54,269 - Check out aj. 166 00:05:54,355 --> 00:05:55,604 - Uh-oh. 167 00:05:55,689 --> 00:05:57,230 - I'm using white out 168 00:05:57,316 --> 00:05:59,608 because I want to make sure that the cannister can pop off 169 00:05:59,693 --> 00:06:01,193 this steel pretty easily 170 00:06:01,278 --> 00:06:03,028 so I know that I have hardenable steel. 171 00:06:03,113 --> 00:06:05,489 - They don't have to peel the tube 172 00:06:05,574 --> 00:06:06,865 off the billet. 173 00:06:06,950 --> 00:06:08,825 - No, they don't have to, and I certainly wouldn't. 174 00:06:08,911 --> 00:06:11,870 I would not put any white out anywhere near this cannister. 175 00:06:11,955 --> 00:06:15,832 I'd use the cannister to keep everything together. 176 00:06:15,918 --> 00:06:17,834 - I get all my materials in the can 177 00:06:17,920 --> 00:06:20,754 and realize that I cut my pipe a little too short. 178 00:06:20,839 --> 00:06:21,838 ♪ ♪ 179 00:06:21,924 --> 00:06:23,799 so I have to redo the can. 180 00:06:23,884 --> 00:06:26,760 - I'd say 80% of our competitions, 181 00:06:26,845 --> 00:06:28,678 if you don't have sacrificial steel, 182 00:06:28,764 --> 00:06:30,263 you're in trouble. 183 00:06:30,349 --> 00:06:33,475 - This time I'm gonna try bringing it up to ten inches. 184 00:06:33,769 --> 00:06:35,268 - Two hours, bladesmiths! 185 00:06:35,354 --> 00:06:38,397 - I'm choosing not to use the white out 186 00:06:38,440 --> 00:06:41,149 because I'm gonna grind off that tube 187 00:06:41,235 --> 00:06:42,317 when I'm done anyways. 188 00:06:42,403 --> 00:06:43,819 Welding! 189 00:06:43,904 --> 00:06:46,571 I know I'll have good high-carbon steel on the edge. 190 00:06:46,657 --> 00:06:48,824 I weld it up and throw it in the forge. 191 00:06:48,909 --> 00:06:50,700 [groans] 192 00:06:50,744 --> 00:06:52,577 I go back to my table. 193 00:06:52,663 --> 00:06:54,538 Oh, my god. 194 00:06:54,623 --> 00:06:57,791 I see ball bearings still on my table 195 00:06:57,876 --> 00:06:59,251 you got to be [bleep] kidding me. 196 00:06:59,294 --> 00:07:02,087 I have to put everything into this can 197 00:07:02,172 --> 00:07:03,171 to meet parameters. 198 00:07:03,257 --> 00:07:04,548 Son of a [bleep]. 199 00:07:04,633 --> 00:07:06,967 I decide I'm gonna cut the end off of it 200 00:07:07,052 --> 00:07:09,219 and try to put the ball bearings back in. 201 00:07:09,304 --> 00:07:11,179 What a [bleep]show. 202 00:07:11,265 --> 00:07:13,014 - It's not all gonna fit. 203 00:07:13,100 --> 00:07:14,975 So I'm trying to fit everything in the cannister. 204 00:07:15,060 --> 00:07:16,601 It's just not fitting. 205 00:07:16,687 --> 00:07:19,354 I dump everything out, try to redo it. 206 00:07:19,440 --> 00:07:21,314 It's not gonna have room. 207 00:07:21,400 --> 00:07:24,025 But my cannister's just too small. 208 00:07:24,111 --> 00:07:25,235 Okay. 209 00:07:25,320 --> 00:07:26,736 - See that zach is having trouble 210 00:07:26,822 --> 00:07:28,572 fitting some of those larger chunks of metal 211 00:07:28,615 --> 00:07:29,906 into his tube. 212 00:07:29,992 --> 00:07:31,741 - Well, he's invested a bunch of time 213 00:07:31,827 --> 00:07:33,160 in squaring up that tube. 214 00:07:33,245 --> 00:07:35,745 So might as well stick with the investment. 215 00:07:35,831 --> 00:07:36,997 ♪ ♪ 216 00:07:37,082 --> 00:07:38,582 - so then it hits me-- 217 00:07:38,667 --> 00:07:40,750 why don't I just make the cannister bigger? 218 00:07:40,836 --> 00:07:43,128 So I'm gonna make a new piece of square tube, 219 00:07:43,172 --> 00:07:44,754 cut a little piece off of it, 220 00:07:44,840 --> 00:07:46,673 and weld everything together. 221 00:07:46,758 --> 00:07:49,593 This is a faster solution than starting over. 222 00:07:49,678 --> 00:07:54,097 ♪ ♪ 223 00:07:54,183 --> 00:07:56,183 - normally you'd use a square can, 224 00:07:56,268 --> 00:07:57,893 so when you're putting it through the press 225 00:07:57,978 --> 00:07:59,227 to forge-weld, 226 00:07:59,313 --> 00:08:00,979 you got your dies set up 227 00:08:01,064 --> 00:08:03,023 so you would get nice, even pressure. 228 00:08:03,108 --> 00:08:05,025 Whereas, with a tube, 229 00:08:05,110 --> 00:08:06,902 you're not gonna get nice, even pressure. 230 00:08:06,987 --> 00:08:09,154 I'm gonna work it slow 231 00:08:09,239 --> 00:08:11,114 like I'm packing a snowball. 232 00:08:11,200 --> 00:08:13,909 You know, if you pack a snowball real slow, 233 00:08:13,994 --> 00:08:15,994 you're gonna get it nice and hard. 234 00:08:16,079 --> 00:08:18,622 My wife, kayla, is a bladesmith, 235 00:08:18,707 --> 00:08:20,832 and she taught me how to forge. 236 00:08:20,876 --> 00:08:23,210 I brought a picture of her and I working in the shop 237 00:08:23,295 --> 00:08:25,504 so I can just try and have the feel 238 00:08:25,547 --> 00:08:27,506 of just a normal day out in the shop with her. 239 00:08:27,591 --> 00:08:29,799 And then I'm standing in front of the forge. 240 00:08:29,885 --> 00:08:32,177 I feel something in my pocket, 241 00:08:32,262 --> 00:08:34,471 and it's a note from my wife. 242 00:08:34,556 --> 00:08:35,931 - It might not be his home forge, 243 00:08:36,016 --> 00:08:37,891 but he's a bringing a little bit of his home with him 244 00:08:37,976 --> 00:08:40,185 to make it more comfortable. - Absolutely. 245 00:08:40,229 --> 00:08:42,020 - Regardless of what the outcome is, 246 00:08:42,064 --> 00:08:43,939 you know, I still get to go home 247 00:08:44,024 --> 00:08:45,982 and work alongside my best friend. 248 00:08:46,068 --> 00:08:48,235 ♪ ♪ 249 00:08:48,320 --> 00:08:50,153 - after I get my metal in the forge, 250 00:08:50,239 --> 00:08:52,322 I'm waiting for it to heat up, 251 00:08:52,407 --> 00:08:54,199 make sure it's hot all the way through. 252 00:08:54,243 --> 00:08:56,451 I'm looking around at my competitors. 253 00:08:56,537 --> 00:08:58,328 If my steel looks like their steel 254 00:08:58,413 --> 00:09:00,705 then maybe I'm ready for a forge weld. 255 00:09:00,791 --> 00:09:02,082 Drawing it out at the press, 256 00:09:02,167 --> 00:09:03,583 it seems like it's going all right, 257 00:09:03,669 --> 00:09:06,002 but it's not moving as quick as I want it. 258 00:09:06,088 --> 00:09:08,672 So I decide I'm gonna take it to the power hammer 259 00:09:08,757 --> 00:09:10,840 because that'll hit it a lot harder. 260 00:09:10,926 --> 00:09:12,968 ♪ ♪ 261 00:09:13,053 --> 00:09:16,680 and the sides blow out. 262 00:09:16,765 --> 00:09:17,722 ♪ ♪ 263 00:09:17,766 --> 00:09:20,058 [bleep]. - Oh, boy. 264 00:09:20,102 --> 00:09:21,268 - I'm thinking I failed. 265 00:09:21,353 --> 00:09:24,688 Nothing welded up. I just have a can. 266 00:09:24,773 --> 00:09:28,358 - I kind of think that aj is not getting that can off. 267 00:09:28,443 --> 00:09:29,442 - Nope. 268 00:09:29,528 --> 00:09:31,069 - He has forged it beyond the point 269 00:09:31,154 --> 00:09:33,029 where that can can be removed. 270 00:09:33,073 --> 00:09:34,906 - I'm gonna cut it, 271 00:09:34,950 --> 00:09:36,700 and everything's gonna spill out, 272 00:09:36,785 --> 00:09:38,326 and I'll have to start again 273 00:09:38,412 --> 00:09:39,953 with an hour left on the clock. 274 00:09:40,038 --> 00:09:43,540 - I give his odds of success a 20%. 275 00:09:43,625 --> 00:09:46,209 - Either way, he's got to make a decision now. 276 00:09:46,295 --> 00:09:48,169 - This could send me home. 277 00:09:48,255 --> 00:09:50,171 [bleep]. 278 00:09:52,843 --> 00:09:53,842 ♪ ♪ 279 00:09:53,927 --> 00:09:55,343 - I'm thinking that this is a failure. 280 00:09:55,429 --> 00:09:57,929 So I start to peel the can off. 281 00:09:57,973 --> 00:10:00,098 ♪ ♪ 282 00:10:00,183 --> 00:10:01,433 - you know what? I'm hearing hollow. 283 00:10:01,518 --> 00:10:02,601 - So am I. 284 00:10:02,644 --> 00:10:04,227 ♪ ♪ 285 00:10:04,271 --> 00:10:06,062 - I see that the can's popping, 286 00:10:06,106 --> 00:10:07,606 and not only is it popping, 287 00:10:07,649 --> 00:10:10,108 I could see that there's usable steel under there. 288 00:10:10,152 --> 00:10:11,276 ♪ ♪ 289 00:10:11,361 --> 00:10:12,694 - ha, look at that! [laughs] 290 00:10:12,779 --> 00:10:14,279 unbelievable. 291 00:10:14,323 --> 00:10:16,114 That can fell off of there. - [laughs] 292 00:10:16,199 --> 00:10:17,449 wow. 293 00:10:17,534 --> 00:10:18,950 - I truly don't believe that. 294 00:10:18,994 --> 00:10:20,952 - I'm thinking I should go buy a lottery ticket, 295 00:10:20,996 --> 00:10:23,747 because not only did the metal weld, 296 00:10:23,790 --> 00:10:25,624 the can popped off. 297 00:10:25,667 --> 00:10:28,043 Now I can start forging my blade. 298 00:10:28,128 --> 00:10:31,087 - Bladesmiths, you got one hour remaining! 299 00:10:31,173 --> 00:10:33,340 - I feel pretty content. 300 00:10:33,425 --> 00:10:36,134 My billet, it's big enough to make a sword out of it, 301 00:10:36,178 --> 00:10:38,803 but I'm just happy that I know I have enough steel, 302 00:10:38,847 --> 00:10:41,973 and from here, I can just chop off the end of it. 303 00:10:42,017 --> 00:10:44,976 ♪ ♪ 304 00:10:45,020 --> 00:10:47,145 - what an interesting hammer stroke. 305 00:10:47,189 --> 00:10:48,938 It never comes above his chin really. 306 00:10:49,024 --> 00:10:50,774 - But his chin is eight feet off the ground. 307 00:10:50,817 --> 00:10:53,151 - [laughing] there's that. 308 00:10:53,195 --> 00:10:55,654 - I'm just finishing up making my full tang. 309 00:10:55,739 --> 00:10:57,614 Everything's smooth. 310 00:10:57,699 --> 00:11:00,283 - Whoa, whoa, whoa! - What happened? What happened? 311 00:11:00,327 --> 00:11:01,826 - Kyle's making a full-tang knife. 312 00:11:01,912 --> 00:11:04,663 He needs to make a through tang or a hidden tang. 313 00:11:04,706 --> 00:11:05,872 ♪ ♪ 314 00:11:05,957 --> 00:11:07,582 - I look over, see kyle hammering out 315 00:11:07,668 --> 00:11:10,669 what looks like the profile of a full-tang knife. 316 00:11:10,712 --> 00:11:12,253 ♪ ♪ 317 00:11:12,339 --> 00:11:14,005 it's a competition, there's a lot of money on the line, 318 00:11:14,049 --> 00:11:16,341 but I don't want to win on account of somebody 319 00:11:16,426 --> 00:11:18,677 getting knocked out for a parameter. 320 00:11:18,720 --> 00:11:20,512 - It looks like zach wants to say something. 321 00:11:20,555 --> 00:11:21,513 - Yeah. 322 00:11:21,598 --> 00:11:23,223 - Yep, wait. Hold on. 323 00:11:23,308 --> 00:11:25,517 - You doing a hidden tang? - No. 324 00:11:25,560 --> 00:11:28,061 - I think we have to. - Something's being said. 325 00:11:28,146 --> 00:11:29,729 - Really? - Yeah. 326 00:11:29,815 --> 00:11:32,315 - Maybe check, but I'm pretty sure. 327 00:11:32,359 --> 00:11:36,152 The instructor in me just wouldn't let it go, 328 00:11:36,238 --> 00:11:38,530 because we teach our students 329 00:11:38,573 --> 00:11:41,366 to keep an eye out for everyone 330 00:11:41,410 --> 00:11:42,450 and everything around them, 331 00:11:42,536 --> 00:11:43,785 and that's what I intend to do here. 332 00:11:43,870 --> 00:11:45,453 - Our smiths, 333 00:11:45,539 --> 00:11:48,039 they can ask the challenge department 334 00:11:48,083 --> 00:11:49,541 for a clarification. 335 00:11:50,794 --> 00:11:51,960 - And here they go. 336 00:11:52,045 --> 00:11:53,211 - Here they go. - Bingo. 337 00:11:55,132 --> 00:11:57,549 - Oh, okay. 338 00:11:57,592 --> 00:11:59,676 - I would want them to say something to me 339 00:11:59,720 --> 00:12:01,302 just like I did to kyle. 340 00:12:01,388 --> 00:12:03,972 - That's what I love about this competition. 341 00:12:04,057 --> 00:12:05,014 - Absolutely. 342 00:12:05,058 --> 00:12:06,349 - The community of bladesmiths 343 00:12:06,393 --> 00:12:08,351 are always helping each other. 344 00:12:08,437 --> 00:12:09,894 - I'm grateful for zach. 345 00:12:09,980 --> 00:12:11,354 If I had gone any further, 346 00:12:11,440 --> 00:12:13,690 there would've been really no fixing it after that. 347 00:12:13,775 --> 00:12:16,359 I would've totally missed parameters. 348 00:12:16,445 --> 00:12:18,903 - You got 30 minutes remaining! 349 00:12:18,947 --> 00:12:20,280 - I'm grinding the blade, 350 00:12:20,365 --> 00:12:22,741 and I notice down at the edge, there's some-- 351 00:12:22,784 --> 00:12:25,076 it looks like cracks along the edge. 352 00:12:25,162 --> 00:12:27,746 And that's just the worst. 353 00:12:27,831 --> 00:12:29,581 I don't want to play with it too much 354 00:12:29,624 --> 00:12:31,666 just because I'd rather have the thickness 355 00:12:31,752 --> 00:12:34,753 to correct something than make it really thin 356 00:12:34,796 --> 00:12:37,422 and a little vulnerable in the strength test. 357 00:12:37,466 --> 00:12:39,340 ♪ ♪ 358 00:12:39,426 --> 00:12:40,800 - ah! 359 00:12:40,886 --> 00:12:42,594 He's got the kill it quench! 360 00:12:42,637 --> 00:12:44,929 - Lo and behold, no warps at all. 361 00:12:44,973 --> 00:12:45,889 ♪ ♪ 362 00:12:45,974 --> 00:12:47,640 I just need to grind some more 363 00:12:47,726 --> 00:12:50,101 to get down to that good high-carbon steel. 364 00:12:50,145 --> 00:12:51,436 ♪ ♪ 365 00:12:51,480 --> 00:12:54,856 - bladesmiths, you got ten minutes remaining! 366 00:12:54,941 --> 00:12:57,192 - There we go. - Okay, kyle just quenched! 367 00:12:57,277 --> 00:12:59,444 - Nice. 368 00:12:59,488 --> 00:13:00,779 - I take it out of the quench, 369 00:13:00,822 --> 00:13:02,447 and it's like I'm looking at a banana. 370 00:13:02,491 --> 00:13:04,324 So I try and straighten it out 371 00:13:04,409 --> 00:13:06,201 by applying some pressure on it. 372 00:13:06,286 --> 00:13:07,911 - With all that mild steel 373 00:13:07,954 --> 00:13:09,412 jacketing that blade, 374 00:13:09,498 --> 00:13:11,790 he actually can bend it quite a bit. 375 00:13:11,833 --> 00:13:18,213 ♪ ♪ 376 00:13:18,298 --> 00:13:20,965 - aj quenched. 377 00:13:21,009 --> 00:13:23,802 - I notice it's got a bit of a warp to it. 378 00:13:23,845 --> 00:13:26,471 So I'm gonna go for a second quench. 379 00:13:26,515 --> 00:13:29,140 ♪ ♪ 380 00:13:29,184 --> 00:13:30,642 still got a bit of a warp, 381 00:13:30,727 --> 00:13:33,102 but I left enough thickness 382 00:13:33,146 --> 00:13:34,979 that I can grind it out. 383 00:13:35,023 --> 00:13:37,482 - Bladesmiths, you got five minutes remaining! 384 00:13:37,567 --> 00:13:38,650 - Little more. 385 00:13:38,693 --> 00:13:39,943 ♪ ♪ 386 00:13:40,028 --> 00:13:42,487 - nice. Good quench. 387 00:13:42,531 --> 00:13:43,530 ♪ ♪ 388 00:13:43,615 --> 00:13:45,240 - it looks good, it feels good, 389 00:13:45,325 --> 00:13:48,326 but I haven't measured my blade in a while. 390 00:13:48,370 --> 00:13:50,286 ♪ ♪ 391 00:13:50,330 --> 00:13:51,871 [bleep]. 392 00:13:51,957 --> 00:13:56,125 My blade is about 3/4 inch shy of that 14-inch mark. 393 00:13:56,169 --> 00:13:57,585 [bleep]. 394 00:13:57,671 --> 00:13:59,963 They're measuring my blade from tip to plunge. 395 00:14:00,006 --> 00:14:02,173 So I make the decision 396 00:14:02,217 --> 00:14:03,883 to cut a new plunge grind 397 00:14:03,969 --> 00:14:06,511 behind where I really wanted it to be. 398 00:14:06,596 --> 00:14:09,848 This is gonna, in effect, make the blade longer. 399 00:14:09,933 --> 00:14:12,433 - Five, four, 400 00:14:12,519 --> 00:14:15,311 three, two, one! 401 00:14:15,355 --> 00:14:16,855 Bladesmiths, your time is up! 402 00:14:16,898 --> 00:14:19,691 Turn off your machines, put down your work! 403 00:14:19,734 --> 00:14:21,150 This round is over! 404 00:14:21,236 --> 00:14:22,443 - [laughs] - [bleep]. 405 00:14:22,529 --> 00:14:24,153 - Good job. - [laughs] 406 00:14:24,239 --> 00:14:25,697 [dramatic music] 407 00:14:25,740 --> 00:14:27,657 - overall, except for that plunge grind, 408 00:14:27,742 --> 00:14:29,659 I'm pretty happy with the blade. 409 00:14:29,744 --> 00:14:31,035 It's pretty straight, 410 00:14:31,121 --> 00:14:32,704 it's pretty even, 411 00:14:32,789 --> 00:14:35,206 but likelihood that I'm gonna move on to round two, 412 00:14:35,250 --> 00:14:36,875 I'm gonna call it a 50/50. 413 00:14:36,918 --> 00:14:39,836 ♪ ♪ 414 00:14:39,921 --> 00:14:41,087 - all right, guys, congratulations. 415 00:14:41,172 --> 00:14:42,714 You made it through round one. 416 00:14:42,757 --> 00:14:45,008 You had 3 hours to come out with a knife 417 00:14:45,093 --> 00:14:47,552 between 14 and 16 inches. 418 00:14:47,596 --> 00:14:49,846 Now the judges have some critiques to give. 419 00:14:49,890 --> 00:14:51,306 Kyle, you're up first. 420 00:14:51,391 --> 00:14:53,391 Please present your work. 421 00:14:53,435 --> 00:14:56,561 ♪ ♪ 422 00:14:56,605 --> 00:14:59,314 - all right, kyle, your welds look really solid, 423 00:14:59,399 --> 00:15:00,398 which I like. 424 00:15:00,483 --> 00:15:01,733 Major concerns I have 425 00:15:01,776 --> 00:15:03,401 are the transition here to the tang. 426 00:15:03,486 --> 00:15:05,528 It just kind of goes into 427 00:15:05,572 --> 00:15:07,280 a pretty lean tang right away. 428 00:15:07,365 --> 00:15:09,824 So anything you can do to work on that transition 429 00:15:09,910 --> 00:15:12,243 would probably be a good idea. - Thank you. 430 00:15:12,287 --> 00:15:14,078 - All right, ben, you ready? 431 00:15:14,122 --> 00:15:16,247 Come on up and present your work to your judges. 432 00:15:16,291 --> 00:15:20,710 ♪ ♪ 433 00:15:20,795 --> 00:15:24,297 - so, ben, first off, there's a heck of a lot of metal here. 434 00:15:24,382 --> 00:15:26,424 Would love to see you refine these grinds. 435 00:15:26,468 --> 00:15:28,760 I can see the hardened steel along the edge. 436 00:15:28,803 --> 00:15:30,094 That's good. 437 00:15:30,138 --> 00:15:32,221 Altogether, looks like a solid, sturdy blade. 438 00:15:32,265 --> 00:15:33,932 - Thank you. - All right, aj. 439 00:15:33,975 --> 00:15:35,934 Please present your work to the judges. 440 00:15:35,977 --> 00:15:41,189 ♪ ♪ 441 00:15:41,274 --> 00:15:43,858 - all right, aj, peeling the can off is the right way to go, 442 00:15:43,944 --> 00:15:45,860 but it does take away a relatively significant 443 00:15:45,946 --> 00:15:47,236 amount of steel. 444 00:15:47,322 --> 00:15:50,448 But the one thing here that gives me the most pause 445 00:15:50,492 --> 00:15:52,325 is there's a delamination right here on the spine, 446 00:15:52,410 --> 00:15:54,702 and there's another one a little bit further up 447 00:15:54,788 --> 00:15:56,454 just right here. 448 00:15:56,498 --> 00:15:58,915 But the rest of the blade did weld up. 449 00:15:59,000 --> 00:16:00,500 Nice job. - Thank you. 450 00:16:00,585 --> 00:16:02,126 - All right, zach, that leaves us with you. 451 00:16:02,170 --> 00:16:04,796 Please present your work to the judges. 452 00:16:04,839 --> 00:16:09,175 ♪ ♪ 453 00:16:09,260 --> 00:16:11,803 - all right, zach, let's talk about your blade here. 454 00:16:11,888 --> 00:16:14,889 It's not perfectly straight, but it's not warped either. 455 00:16:14,975 --> 00:16:18,935 What I have a question with is... 456 00:16:18,979 --> 00:16:20,728 What exactly is going on here? 457 00:16:20,814 --> 00:16:22,313 - Right at the end, 458 00:16:22,399 --> 00:16:24,732 realized I came up a little bit short on that length. 459 00:16:24,818 --> 00:16:28,194 So I made the decision to push that plunge grind back, 460 00:16:28,279 --> 00:16:30,154 try to make that 14-inch minimum. 461 00:16:30,198 --> 00:16:31,656 - Got ya. 462 00:16:31,700 --> 00:16:34,200 Because normally you would think with a design like this 463 00:16:34,285 --> 00:16:35,827 from tip to plunge grind 464 00:16:35,870 --> 00:16:38,955 goes right there, and that would've been 12 1/2, 465 00:16:39,040 --> 00:16:42,041 but you marked it further back. 466 00:16:42,127 --> 00:16:44,335 You're at 14 inches. 467 00:16:44,379 --> 00:16:45,503 If you move forward, 468 00:16:45,588 --> 00:16:47,880 there might be some reprofiling there, 469 00:16:47,966 --> 00:16:50,174 but otherwise, sir, it's a solid piece of work. 470 00:16:50,260 --> 00:16:51,300 - Thank you. 471 00:16:51,386 --> 00:16:53,428 - All right, bladesmiths. 472 00:16:53,513 --> 00:16:55,847 You all came through with workable blades. 473 00:16:55,932 --> 00:16:58,516 Unfortunately, the judges have made their final decision, 474 00:16:58,560 --> 00:17:00,935 and the bladesmith not moving forward 475 00:17:01,021 --> 00:17:04,313 is gonna be... 476 00:17:04,399 --> 00:17:05,648 Aj. 477 00:17:05,734 --> 00:17:07,191 Ben's gonna tell you why. 478 00:17:07,235 --> 00:17:09,110 - Well, aj, coming out of round one, 479 00:17:09,195 --> 00:17:10,945 of the four blades, yours is the only one 480 00:17:11,031 --> 00:17:12,864 that has structural problems in the steel, 481 00:17:12,907 --> 00:17:14,282 and that's why we're sending you home. 482 00:17:14,367 --> 00:17:15,324 - I understand. 483 00:17:15,410 --> 00:17:16,868 - All right, aj, at this point, 484 00:17:16,911 --> 00:17:18,494 I'm gonna have to ask you to surrender your weapon 485 00:17:18,580 --> 00:17:21,039 and please leave the forge floor. 486 00:17:21,082 --> 00:17:23,207 - I'm pretty happy with what I ended up with, 487 00:17:23,251 --> 00:17:26,461 considering it was a tube cannister damascus, 488 00:17:26,546 --> 00:17:28,546 which they've never done on this competition before. 489 00:17:28,590 --> 00:17:30,048 - Good work. - Well fought, brother. 490 00:17:30,091 --> 00:17:31,382 - Good luck. 491 00:17:31,426 --> 00:17:34,010 Going home, I'll probably only ever see 492 00:17:34,095 --> 00:17:35,887 a tube cannister in my nightmares. 493 00:17:35,972 --> 00:17:37,555 I would call this challenge, like, 494 00:17:37,640 --> 00:17:39,849 the quiche of damascus, 'cause it was just disgusting. 495 00:17:39,934 --> 00:17:43,227 It was--it was-- it was hard. 496 00:17:43,271 --> 00:17:44,395 ♪ ♪ 497 00:17:44,439 --> 00:17:45,730 - all right, guys, congratulations. 498 00:17:45,774 --> 00:17:46,814 The three of you will be moving forward 499 00:17:46,900 --> 00:17:48,399 into round two of the competition. 500 00:17:48,485 --> 00:17:51,152 In this round, I want you guys to add handles to your blades. 501 00:17:51,237 --> 00:17:52,403 You'll see on your work stations, 502 00:17:52,447 --> 00:17:54,447 you each have six pieces of round stock. 503 00:17:54,532 --> 00:17:56,115 I want to use those 504 00:17:56,201 --> 00:17:59,619 to make spiraled fluted handles. 505 00:17:59,704 --> 00:18:01,579 You guys will only have two hours 506 00:18:01,623 --> 00:18:03,748 to complete this next round of the competition, 507 00:18:03,833 --> 00:18:06,250 after which we will be testing your strength and durability 508 00:18:06,294 --> 00:18:08,002 in the steel wind chime chop 509 00:18:08,088 --> 00:18:10,755 and checking for sharpness in a rubber tube slice. 510 00:18:10,840 --> 00:18:14,258 Good luck, bladesmiths. Your time starts now. 511 00:18:14,344 --> 00:18:16,761 [rock music] 512 00:18:16,805 --> 00:18:17,929 oh, right. 513 00:18:17,972 --> 00:18:19,597 - So I got a question for you guys. 514 00:18:19,682 --> 00:18:22,683 What is a good rule for fluting on the handle? 515 00:18:22,769 --> 00:18:24,393 - You want to make a comfortable handle 516 00:18:24,479 --> 00:18:26,104 before you start doing any fluting. 517 00:18:26,147 --> 00:18:28,022 ♪ ♪ 518 00:18:28,108 --> 00:18:30,441 - coming out of round one, I got some feedback 519 00:18:30,527 --> 00:18:33,277 from the judges regarding the straightness of my blade. 520 00:18:33,363 --> 00:18:36,280 So I do plan on using the grinder, 521 00:18:36,366 --> 00:18:39,617 try straighten out some of that wobble that I've got. 522 00:18:39,661 --> 00:18:40,785 ♪ ♪ 523 00:18:40,829 --> 00:18:42,120 little concerned about that clock. 524 00:18:42,163 --> 00:18:43,454 Two hours is pretty short 525 00:18:43,498 --> 00:18:45,289 to make a hidden tang with a flute. 526 00:18:45,333 --> 00:18:48,626 ♪ ♪ 527 00:18:48,711 --> 00:18:52,004 - dave mentioned that he was a little worried 528 00:18:52,090 --> 00:18:54,799 about the integrity of my tang. 529 00:18:54,843 --> 00:18:56,259 So, going into the second round, 530 00:18:56,302 --> 00:18:58,678 I'm going to beef up my tang 531 00:18:58,763 --> 00:19:01,305 where dave had said his main concern was. 532 00:19:01,349 --> 00:19:03,307 ♪ ♪ 533 00:19:03,351 --> 00:19:05,434 I have no idea what's going on around me. 534 00:19:05,478 --> 00:19:07,562 I just want to focus on my own work 535 00:19:07,647 --> 00:19:09,480 and make sure that I can turn in a finished blade. 536 00:19:09,524 --> 00:19:11,774 ♪ ♪ 537 00:19:11,860 --> 00:19:14,152 - 90 minutes remaining on the clock! 538 00:19:14,195 --> 00:19:16,154 You've got 90 minutes left! 539 00:19:16,197 --> 00:19:18,156 ♪ ♪ 540 00:19:18,241 --> 00:19:21,159 - so my plan is to tackle the handle first. 541 00:19:21,202 --> 00:19:23,161 ♪ ♪ 542 00:19:23,204 --> 00:19:24,954 - ben's doing the "throw it at the floor" test. 543 00:19:25,039 --> 00:19:26,622 - There you go. 544 00:19:26,666 --> 00:19:27,665 - Is he checking the strength of them? 545 00:19:27,750 --> 00:19:28,916 - Yeah. - Yeah. 546 00:19:29,002 --> 00:19:30,293 - Some of the stuff can be really brittle. 547 00:19:30,336 --> 00:19:31,961 - If anything blatantly shatters, 548 00:19:32,046 --> 00:19:33,588 I shouldn't use that if it does. 549 00:19:33,673 --> 00:19:34,839 ♪ yeah ♪ 550 00:19:34,883 --> 00:19:37,466 ♪ ♪ 551 00:19:37,510 --> 00:19:39,760 - kyle's looking for one with brass. 552 00:19:39,846 --> 00:19:43,181 - I know I want to use brass to make a guard and a pommel 553 00:19:43,266 --> 00:19:44,807 to add a little bit of counterweight 554 00:19:44,893 --> 00:19:46,517 for such a large blade. 555 00:19:46,561 --> 00:19:47,977 ♪ ♪ 556 00:19:48,062 --> 00:19:51,230 but it's not cooperating with me. 557 00:19:51,316 --> 00:19:53,649 - It's the wrong tool. 558 00:19:53,735 --> 00:19:54,734 Brass, when you heat it up 559 00:19:54,819 --> 00:19:56,027 with one of those cutoff wheels, 560 00:19:56,112 --> 00:19:58,946 gets sticky and starts coating the blade, 561 00:19:59,032 --> 00:20:02,200 and then they stop working and just make things hot. 562 00:20:02,243 --> 00:20:03,576 ♪ ♪ 563 00:20:03,661 --> 00:20:05,453 - I'm not making any progress whatsoever 564 00:20:05,538 --> 00:20:08,164 trying to get through that piece of brass. 565 00:20:08,208 --> 00:20:09,373 [bleep]. 566 00:20:09,417 --> 00:20:10,708 ♪ ♪ 567 00:20:10,793 --> 00:20:13,836 you know, I've got two hours to try and make it work. 568 00:20:13,922 --> 00:20:15,213 Every mistake is a big mistake, 569 00:20:15,298 --> 00:20:16,923 and it could set me back quite a bit. 570 00:20:17,008 --> 00:20:18,549 - There is a lot to be done here. 571 00:20:18,593 --> 00:20:20,218 This is not an easy handle. 572 00:20:20,261 --> 00:20:22,553 - 45 minutes remaining on the clock! 573 00:20:22,597 --> 00:20:26,057 - [bleep]. 574 00:20:26,142 --> 00:20:28,100 A job with the wrong tool, 575 00:20:28,186 --> 00:20:29,518 you're just gonna waste your time. 576 00:20:29,604 --> 00:20:31,354 - I take it over to the bandsaw, 577 00:20:31,439 --> 00:20:33,022 where I should've started, 578 00:20:33,107 --> 00:20:34,941 and no issues getting through it. 579 00:20:35,026 --> 00:20:36,817 ♪ ♪ 580 00:20:36,903 --> 00:20:40,529 - ben's the first one on the grinder putting his flutes in. 581 00:20:40,615 --> 00:20:43,115 - [laughs] oh, it's horrible. 582 00:20:43,201 --> 00:20:45,451 The flutes that I just put in are not gonna work. 583 00:20:45,536 --> 00:20:46,869 It just doesn't feel good in my hand. 584 00:20:46,955 --> 00:20:48,454 It's way too big. 585 00:20:48,539 --> 00:20:52,041 - He put the fluting in before he started shaping his handle, 586 00:20:52,126 --> 00:20:53,584 so isn't he just gonna lose the fluting? 587 00:20:53,670 --> 00:20:54,710 - Yeah. - Yeah. 588 00:20:54,796 --> 00:20:56,128 - I need to take more material 589 00:20:56,214 --> 00:20:57,630 off of this handle first. 590 00:20:57,715 --> 00:20:59,048 - He's gonna have to go back and do it again. 591 00:20:59,133 --> 00:21:00,716 - Yep. [laughs] 592 00:21:00,802 --> 00:21:03,761 - he just took 30 minutes and chucked them out the window. 593 00:21:03,846 --> 00:21:05,638 - I need to stop doing this 594 00:21:05,723 --> 00:21:07,723 because it's sucking up too much time. 595 00:21:07,809 --> 00:21:10,059 I want to just get the handle shaped, 596 00:21:10,144 --> 00:21:12,436 and then I'll take the dremel 597 00:21:12,522 --> 00:21:15,231 and put flutes in smaller by hand. 598 00:21:15,316 --> 00:21:17,275 ♪ ♪ 599 00:21:17,360 --> 00:21:19,568 - ten minutes remaining on the clock! 600 00:21:19,654 --> 00:21:21,237 ♪ ♪ 601 00:21:21,281 --> 00:21:23,823 - has zach fluted anything? - No. 602 00:21:23,908 --> 00:21:25,116 ♪ ♪ 603 00:21:25,159 --> 00:21:26,367 - right now I'm feeling confident 604 00:21:26,452 --> 00:21:27,910 in the time that I have 605 00:21:27,996 --> 00:21:29,578 and the amount that I have to get done on this knife. 606 00:21:29,664 --> 00:21:31,205 The last thing that I want 607 00:21:31,291 --> 00:21:34,083 is to go home on account of an uncomfortable handle. 608 00:21:34,168 --> 00:21:35,668 - Now would be a good payback for kyle. 609 00:21:35,753 --> 00:21:37,753 "hey, zach, you're about to miss parameters." 610 00:21:37,839 --> 00:21:39,797 - I want to spend the last five minutes 611 00:21:39,882 --> 00:21:41,090 working on my edge. 612 00:21:41,175 --> 00:21:42,258 I know that this is cutting it close, 613 00:21:42,343 --> 00:21:43,843 but I'm pretty sure that I can do it. 614 00:21:43,928 --> 00:21:45,970 - Five minutes remaining! 615 00:21:46,055 --> 00:21:48,889 - You can throw flutes on a blade in a minute, 616 00:21:48,975 --> 00:21:50,349 if you've done it before. 617 00:21:50,435 --> 00:21:53,227 ♪ ♪ 618 00:21:53,313 --> 00:21:56,063 - I decide to put my handle on first, 619 00:21:56,149 --> 00:21:57,440 remove a ton of material, 620 00:21:57,525 --> 00:22:00,192 get the basic shape of my handle done. 621 00:22:00,278 --> 00:22:01,610 ♪ ♪ 622 00:22:01,696 --> 00:22:03,154 I'm holding on to this thing, 623 00:22:03,239 --> 00:22:05,114 and I'm thinking about what my wife told me-- 624 00:22:05,199 --> 00:22:07,325 "make sure you make it so it fits everybody else's hand 625 00:22:07,410 --> 00:22:08,784 and not just yours." 626 00:22:08,870 --> 00:22:11,454 and then I look over at ben abbott, and I'm like, 627 00:22:11,539 --> 00:22:13,080 "this guy's got tiny, little hands. 628 00:22:13,166 --> 00:22:14,874 I hope this thing fits in his hand." 629 00:22:14,959 --> 00:22:16,709 - 20 seconds remaining! 630 00:22:16,794 --> 00:22:22,131 ♪ ♪ 631 00:22:22,216 --> 00:22:23,924 five, four, 632 00:22:24,010 --> 00:22:26,969 three, two, one! 633 00:22:27,055 --> 00:22:28,512 Bladesmiths, this round is over. 634 00:22:28,598 --> 00:22:30,097 Put down your blades. 635 00:22:30,183 --> 00:22:31,432 Stop what you're doing. 636 00:22:31,517 --> 00:22:33,184 [dramatic music] 637 00:22:33,269 --> 00:22:35,436 - I'm pleased with what I have in front of me. 638 00:22:35,521 --> 00:22:36,937 I can't believe that I've pulled off that handle 639 00:22:37,023 --> 00:22:38,272 in two hours, 640 00:22:38,358 --> 00:22:40,024 and then I take a look 641 00:22:40,068 --> 00:22:42,276 at the blade to my left and my right. 642 00:22:42,362 --> 00:22:44,987 My heart sinks. 643 00:22:45,073 --> 00:22:46,989 I've forgotten to put those flutes on the handle. 644 00:22:47,075 --> 00:22:48,657 [sighs] 645 00:22:48,743 --> 00:22:50,868 ♪ ♪ 646 00:22:50,953 --> 00:22:53,829 - all right, gentlemen, I think you know what time it is. 647 00:22:53,915 --> 00:22:55,373 It's time for the strength test. 648 00:22:55,416 --> 00:22:57,500 To test the strength and overall durability 649 00:22:57,585 --> 00:22:58,918 of your blades, 650 00:22:59,003 --> 00:23:00,378 I'll chopping into these steel wind chimes. 651 00:23:00,421 --> 00:23:01,962 Now, this is not about what your blades do 652 00:23:02,048 --> 00:23:03,172 to those wind chimes. 653 00:23:03,257 --> 00:23:05,216 It's about what those wind chimes do 654 00:23:05,301 --> 00:23:07,218 to the edge of your blade. 655 00:23:07,303 --> 00:23:08,386 Ben, you're up first. You ready for this? 656 00:23:08,471 --> 00:23:09,720 - Yes, sir. 657 00:23:09,806 --> 00:23:11,555 I'm a little concerned about my edge. 658 00:23:11,641 --> 00:23:14,558 I just hope that the chimes aren't too big of a deal 659 00:23:14,644 --> 00:23:16,936 and my knife doesn't snap or something like that. 660 00:23:17,021 --> 00:23:24,026 ♪ ♪ 661 00:23:39,877 --> 00:23:41,377 - ben, a lot of the weight's still in this blade 662 00:23:41,462 --> 00:23:43,212 from when we evaluated it-- it didn't get much lighter. 663 00:23:43,297 --> 00:23:44,422 As a matter of fact, 664 00:23:44,507 --> 00:23:45,714 adding that guard probably added more weight, 665 00:23:45,800 --> 00:23:47,383 and there's not a lot of counterbalance. 666 00:23:47,468 --> 00:23:48,926 As far as hitting the pipes go, 667 00:23:49,011 --> 00:23:51,387 you can see that there are some rolled-over sections, 668 00:23:51,472 --> 00:23:52,680 packed-out sections, 669 00:23:52,765 --> 00:23:54,849 and certainly sections where you've lost your edge, 670 00:23:54,934 --> 00:23:57,768 but it's solid, one piece-- good job. 671 00:23:57,854 --> 00:23:58,769 - Cool. Thanks. 672 00:23:58,855 --> 00:24:00,062 - All right, kyle, you're up next. 673 00:24:00,148 --> 00:24:01,147 You ready? - Hell, yeah. 674 00:24:01,232 --> 00:24:02,440 - Good. 675 00:24:02,483 --> 00:24:05,401 - I'm a little bit nervous about my edge. 676 00:24:05,486 --> 00:24:07,736 I designed it more for the sharpness test 677 00:24:07,822 --> 00:24:10,156 as opposed to the strength test. 678 00:24:10,241 --> 00:24:12,241 I hope when dave's done hitting these wind chimes, 679 00:24:12,326 --> 00:24:13,909 my blade is in one piece. 680 00:24:13,995 --> 00:24:20,624 ♪ ♪ 681 00:24:25,673 --> 00:24:27,840 - okay, kyle, first off, hold up your hand. 682 00:24:27,925 --> 00:24:29,925 Yeah, I figured. [laughs] 683 00:24:30,011 --> 00:24:32,928 you got some big mitts, man. That's a big handle. 684 00:24:33,014 --> 00:24:34,221 - [laughs] 685 00:24:34,265 --> 00:24:36,098 I don't know. I don't think they're that big. 686 00:24:36,184 --> 00:24:38,142 - As far as how your blade did, 687 00:24:38,227 --> 00:24:40,186 you've got plenty of edge still left on this blade, 688 00:24:40,271 --> 00:24:43,230 but you can see here where you've got a lot of rolling. 689 00:24:43,316 --> 00:24:45,316 But there's still a lot of edge on this knife. 690 00:24:45,401 --> 00:24:46,442 So good job. 691 00:24:46,527 --> 00:24:47,485 - Awesome. Thanks, dave. 692 00:24:47,570 --> 00:24:49,487 - You bet. All right, zach. 693 00:24:49,572 --> 00:24:50,696 You ready? - Yes, sir. 694 00:24:50,781 --> 00:24:51,697 - Okay. 695 00:24:51,782 --> 00:24:53,157 ♪ ♪ 696 00:24:53,201 --> 00:24:55,284 - I don't know what the judges are gonna say. 697 00:24:55,369 --> 00:24:57,536 If not for that one parameter, 698 00:24:57,622 --> 00:25:00,122 I believe that my knife would do well 699 00:25:00,208 --> 00:25:02,541 through the strength and sharpness test. 700 00:25:02,627 --> 00:25:04,710 Hopefully they're gonna decide to test it. 701 00:25:04,795 --> 00:25:06,086 ♪ ♪ 702 00:25:09,133 --> 00:25:11,258 osed to the strength test. 703 00:25:11,344 --> 00:25:13,385 I hope when dave's done hitting these wind chimes, 704 00:25:13,471 --> 00:25:15,012 my blade is in one piece. 705 00:25:15,056 --> 00:25:21,685 ♪ ♪ 706 00:25:26,734 --> 00:25:28,943 - okay, kyle, first off, hold up your hand. 707 00:25:29,028 --> 00:25:31,028 Yeah, I figured. [laughs] 708 00:25:31,072 --> 00:25:34,031 you got some big mitts, man. That's a big handle. 709 00:25:34,075 --> 00:25:35,241 - [laughs] 710 00:25:35,326 --> 00:25:37,201 I don't know. I don't think they're that big. 711 00:25:37,245 --> 00:25:39,245 - As far as how your blade did, 712 00:25:39,330 --> 00:25:41,288 you've got plenty of edge still left on this blade, 713 00:25:41,374 --> 00:25:44,291 but you can see here where you've got a lot of rolling. 714 00:25:44,377 --> 00:25:46,377 But there's still a lot of edge on this knife. 715 00:25:46,462 --> 00:25:47,545 So good job. 716 00:25:47,588 --> 00:25:48,546 - Awesome. Thanks, dave. 717 00:25:48,631 --> 00:25:50,631 - You bet. All right, zach. 718 00:25:50,716 --> 00:25:51,799 You ready? - Yes, sir. 719 00:25:51,884 --> 00:25:52,800 - Okay. 720 00:25:52,885 --> 00:25:54,218 ♪ ♪ 721 00:25:54,303 --> 00:25:56,387 - I don't know what the judges are gonna say. 722 00:25:56,430 --> 00:25:58,597 If not for that one parameter, 723 00:25:58,683 --> 00:26:01,225 I believe that my knife would do well 724 00:26:01,269 --> 00:26:03,644 through the strength and sharpness test. 725 00:26:03,729 --> 00:26:05,813 Hopefully they're gonna decide to test it. 726 00:26:05,898 --> 00:26:07,189 ♪ ♪ 727 00:26:09,026 --> 00:26:11,819 - right now I'm really hoping that my blade will get tested. 728 00:26:11,904 --> 00:26:13,404 ♪ ♪ 729 00:26:13,447 --> 00:26:14,863 - [whispering] hey, guys. 730 00:26:14,949 --> 00:26:16,782 - I know in the back of my head, 731 00:26:16,867 --> 00:26:18,534 I don't have those flutes. 732 00:26:19,996 --> 00:26:21,370 ♪ ♪ 733 00:26:22,832 --> 00:26:24,373 ♪ ♪ 734 00:26:24,417 --> 00:26:26,250 - you guys all agree? 735 00:26:26,294 --> 00:26:33,007 ♪ ♪ 736 00:26:33,092 --> 00:26:36,051 zach, we asked you guys to give us a fluted handle, 737 00:26:36,095 --> 00:26:37,386 but your knife does not have that. 738 00:26:37,471 --> 00:26:40,598 It was a pleasure watching you in round one. 739 00:26:40,683 --> 00:26:42,933 You helped kyle out with his parameter issues. 740 00:26:42,977 --> 00:26:45,769 Unfortunately, your knife does not meet parameters. 741 00:26:45,855 --> 00:26:47,104 So, for that reason, 742 00:26:47,148 --> 00:26:48,731 I've got to ask you to leave the forge floor. 743 00:26:48,816 --> 00:26:50,774 Thanks for coming out, man. - Thank you. 744 00:26:50,818 --> 00:26:52,276 ♪ ♪ 745 00:26:52,361 --> 00:26:53,944 I agree with the judges. It's the right call. 746 00:26:53,988 --> 00:26:56,447 I missed a parameter. The other guys didn't. 747 00:26:56,490 --> 00:26:57,823 This time around, 748 00:26:57,908 --> 00:26:59,617 I realize I may not have brought my "a" game. 749 00:26:59,702 --> 00:27:01,952 If I get a second chance, I'm bringing it. 750 00:27:01,996 --> 00:27:06,081 ♪ ♪ 751 00:27:06,167 --> 00:27:07,458 - kyle and ben, congratulations. 752 00:27:07,501 --> 00:27:09,418 You guys are moving forward into round three. 753 00:27:09,462 --> 00:27:10,794 Only the man next to you 754 00:27:10,880 --> 00:27:12,129 stands between you, 755 00:27:12,173 --> 00:27:13,589 the title of "forged in fire" champion, 756 00:27:13,633 --> 00:27:15,799 and that coveted check for $10,000. 757 00:27:15,843 --> 00:27:18,135 In round three, we're gonna send you guys back home 758 00:27:18,179 --> 00:27:20,304 to re-create an iconic weapon from history. 759 00:27:20,348 --> 00:27:21,472 That weapon is... 760 00:27:21,515 --> 00:27:24,308 ♪ ♪ 761 00:27:24,393 --> 00:27:26,769 the vajra-mushti. - Wow. 762 00:27:26,854 --> 00:27:28,646 - Originating in india, 763 00:27:28,731 --> 00:27:30,773 the vajra-mushti is an edged knuckle-duster. 764 00:27:30,858 --> 00:27:33,108 The unique design features sharpened blades 765 00:27:33,152 --> 00:27:34,443 on every side of the handle, 766 00:27:34,487 --> 00:27:35,986 making it a specialty weapon 767 00:27:36,072 --> 00:27:38,489 only wielded by well-trained indian warriors. 768 00:27:38,574 --> 00:27:40,324 The sharp edges on all sides 769 00:27:40,368 --> 00:27:42,951 provided the user with a wide range of lethal attacks, 770 00:27:42,995 --> 00:27:45,287 from deadly stabs and slashes 771 00:27:45,373 --> 00:27:46,789 to devastating punches. 772 00:27:46,874 --> 00:27:48,499 A traditional indian martial art 773 00:27:48,542 --> 00:27:50,668 where the weapon is tied to the fist of wrestlers 774 00:27:50,711 --> 00:27:53,003 has lineage dating back to the middle ages 775 00:27:53,089 --> 00:27:54,505 and is still practiced today 776 00:27:54,548 --> 00:27:56,006 by professional wrestlers in india 777 00:27:56,050 --> 00:27:58,842 using nonlethal knuckledusters. 778 00:27:58,928 --> 00:28:00,177 - There's a lot going on here. 779 00:28:00,221 --> 00:28:01,845 I need you to follow these parameters. 780 00:28:01,931 --> 00:28:03,847 Now, you've got two blades on the ends. 781 00:28:03,891 --> 00:28:05,974 They both need to be double-sided 782 00:28:06,018 --> 00:28:07,184 and flamelike or wavy. 783 00:28:07,269 --> 00:28:08,519 The blade on the top 784 00:28:08,562 --> 00:28:09,812 needs to be between 7 and 8 inches. 785 00:28:09,897 --> 00:28:11,188 The blade on the bottom 786 00:28:11,232 --> 00:28:13,357 needs to be between 4 and 5 inches. 787 00:28:13,401 --> 00:28:14,858 Now, your push blade 788 00:28:14,902 --> 00:28:16,402 needs to be between 4 and 5 inches, 789 00:28:16,487 --> 00:28:19,154 with a height of between 1 and 2 inches. 790 00:28:19,240 --> 00:28:20,531 - [sighs] 791 00:28:20,616 --> 00:28:22,658 I don't even know what to say. 792 00:28:22,743 --> 00:28:24,493 The closest thing I've seen to that 793 00:28:24,578 --> 00:28:26,537 is probably a pair of brass knuckles. 794 00:28:26,580 --> 00:28:28,789 - We're gonna send you guys home for four days, 795 00:28:28,874 --> 00:28:31,333 and when you guys come back, I want to see two blades 796 00:28:31,377 --> 00:28:33,502 worth at least $10,000 apiece. 797 00:28:33,587 --> 00:28:35,462 So do your absolute best work. 798 00:28:35,548 --> 00:28:37,506 And good luck. We'll see you in four days. 799 00:28:37,550 --> 00:28:38,507 - Awesome. Good luck, man. 800 00:28:38,551 --> 00:28:40,217 - Good luck. [chuckles] 801 00:28:40,302 --> 00:28:43,053 [rock music] 802 00:28:43,097 --> 00:28:46,724 - day one, I'm about to build a vajra-mushti. 803 00:28:46,809 --> 00:28:48,183 I can't wait to get started with this. 804 00:28:48,269 --> 00:28:51,395 I'm making a at least 70-layer damascus billet. 805 00:28:51,480 --> 00:28:53,731 As long as the forge weld goes good, 806 00:28:53,774 --> 00:28:55,733 I'll be able to draw it out quickly. 807 00:28:55,776 --> 00:28:58,902 I'm about to put my billet in the forge. 808 00:28:58,988 --> 00:29:00,738 I'm feeling marvelous. 809 00:29:00,781 --> 00:29:02,906 Everything's going smooth. 810 00:29:02,992 --> 00:29:05,242 In she goes. 811 00:29:05,286 --> 00:29:07,286 So far, so good with my damascus. 812 00:29:07,371 --> 00:29:09,872 It looks strong, solid. 813 00:29:09,915 --> 00:29:12,416 I still have a long way to go. 814 00:29:12,501 --> 00:29:15,711 It looks like it's gonna forge-weld nicely. 815 00:29:15,796 --> 00:29:21,592 ♪ ♪ 816 00:29:21,635 --> 00:29:23,135 - I feel good to be back home 817 00:29:23,220 --> 00:29:24,887 here in bellows falls, vermont, 818 00:29:24,972 --> 00:29:28,432 and we're going to make the vajra-mushti. 819 00:29:28,517 --> 00:29:31,602 I've never made a vajra-mushti or anything close to it. 820 00:29:31,645 --> 00:29:34,813 So I decided to use 1084 carbon steel 821 00:29:34,899 --> 00:29:37,566 because it's something I'm more familiar with. 822 00:29:37,651 --> 00:29:39,943 I think the most difficult part to the challenge 823 00:29:39,987 --> 00:29:41,445 will be making the handle. 824 00:29:41,489 --> 00:29:43,739 It's something that I'm definitely gonna have 825 00:29:43,783 --> 00:29:45,616 to pay a lot of attention to. 826 00:29:45,659 --> 00:29:47,618 ♪ ♪ 827 00:29:47,661 --> 00:29:49,787 the two smaller blades are basically the same. 828 00:29:49,872 --> 00:29:51,455 One's a little longer than the other, 829 00:29:51,540 --> 00:29:54,625 you know, and then the other blade's just a big rectangle. 830 00:29:54,668 --> 00:29:56,126 ♪ ♪ 831 00:29:56,170 --> 00:29:58,629 five hours into it, I feel pretty good. 832 00:29:58,672 --> 00:30:00,130 ♪ ♪ 833 00:30:00,174 --> 00:30:01,965 one more soak in the forge, 834 00:30:02,009 --> 00:30:04,134 and then I'll quench them. 835 00:30:04,178 --> 00:30:05,928 ♪ ♪ 836 00:30:06,013 --> 00:30:08,430 I got all the forging out of the way, 837 00:30:08,474 --> 00:30:10,057 so I'm feeling good. 838 00:30:10,100 --> 00:30:13,185 End of day one, and I'm really glad I got the heat treat done. 839 00:30:13,270 --> 00:30:14,978 Looks good. 840 00:30:15,064 --> 00:30:16,980 [dogs barking] 841 00:30:17,024 --> 00:30:18,982 ♪ ♪ 842 00:30:19,068 --> 00:30:21,485 - day two, I'm a little tired this morning. 843 00:30:21,529 --> 00:30:24,655 But I feel great, ready to get this show on the road. 844 00:30:24,698 --> 00:30:25,989 My plan for today 845 00:30:26,075 --> 00:30:28,826 is to get as far into this build 846 00:30:28,869 --> 00:30:30,077 as humanly possible. 847 00:30:30,162 --> 00:30:32,996 I got my pattern set out for my knuckle blade, 848 00:30:33,040 --> 00:30:35,249 and I'm just gonna start cutting out the pattern, 849 00:30:35,334 --> 00:30:37,501 and hopefully soon we'll get it welded on. 850 00:30:37,545 --> 00:30:41,505 ♪ ♪ 851 00:30:41,549 --> 00:30:44,132 I got this thing joined up. It's looking good. 852 00:30:44,176 --> 00:30:45,509 I'm not too stressed 853 00:30:45,553 --> 00:30:47,511 that I haven't gotten to the quench yet. 854 00:30:47,555 --> 00:30:50,347 It's been a long time since I used a torch. 855 00:30:50,391 --> 00:30:52,015 ♪ ♪ 856 00:30:52,059 --> 00:30:54,977 I decided that I'm gonna go with a torch heat treatment 857 00:30:55,062 --> 00:30:57,396 because the handle doesn't need to be hard. 858 00:30:57,481 --> 00:31:00,357 I just need the blades hard and the knuckle blade hard. 859 00:31:00,401 --> 00:31:01,692 ♪ ♪ 860 00:31:01,777 --> 00:31:03,527 so I did one, and... 861 00:31:03,571 --> 00:31:04,862 I'm scared I'm gonna crack it in half, 862 00:31:04,905 --> 00:31:07,531 because right after the quench, it is brittle. 863 00:31:07,575 --> 00:31:10,701 So any little shock or hit 864 00:31:10,786 --> 00:31:13,161 could cause catastrophic cracking. 865 00:31:13,247 --> 00:31:15,706 I have to get the next one done. 866 00:31:15,749 --> 00:31:16,707 ♪ ♪ 867 00:31:16,750 --> 00:31:18,876 oh, my god. 868 00:31:18,961 --> 00:31:21,545 If one of these blades has a crack, 869 00:31:21,589 --> 00:31:24,381 I'm honestly not sure what I would do. 870 00:31:24,466 --> 00:31:26,341 You got to be [bleep] kidding me. 871 00:31:29,221 --> 00:31:30,679 Lls out of my vise grips. 872 00:31:30,764 --> 00:31:32,723 And, of course, I have wood floors, 873 00:31:32,766 --> 00:31:34,725 and it falls floor, and it's catching on fire, 874 00:31:34,810 --> 00:31:36,059 and I'm trying to pick it back up. 875 00:31:36,145 --> 00:31:38,437 You got to be [bleep] kidding me. 876 00:31:38,522 --> 00:31:41,899 I'm feeling a lot of anxiety and stress right now. 877 00:31:41,942 --> 00:31:44,401 If one of these blades has a crack, 878 00:31:44,445 --> 00:31:45,736 I'm kind of screwed. 879 00:31:45,779 --> 00:31:46,862 ♪ ♪ 880 00:31:46,947 --> 00:31:49,531 luckily, I don't see any cracks. 881 00:31:49,617 --> 00:31:51,700 So I think the quench went well. 882 00:31:51,744 --> 00:31:53,702 That's gonna have to do. 883 00:31:53,787 --> 00:31:56,079 ♪ ♪ 884 00:31:56,123 --> 00:31:57,581 - it's the beginning of day two, 885 00:31:57,666 --> 00:31:59,082 and I can't wait to get started. 886 00:31:59,126 --> 00:32:00,834 For the handle, I'm gonna go with copper. 887 00:32:00,920 --> 00:32:04,087 It's moving a lot better than I thought it was going to. 888 00:32:04,173 --> 00:32:06,882 I want to pay really close attention to detail. 889 00:32:06,967 --> 00:32:09,092 I want to make a $10,000 knife. 890 00:32:09,136 --> 00:32:10,552 Today I'm able to remove 3 pounds 891 00:32:10,596 --> 00:32:12,930 off a 5-pound chunk of copper 892 00:32:13,015 --> 00:32:14,598 and knocked out a nice workable piece. 893 00:32:14,642 --> 00:32:17,267 Tomorrow I'd like to get the handle all finished up 894 00:32:17,311 --> 00:32:18,977 and the blades fitted on. 895 00:32:19,063 --> 00:32:21,063 That's basically it. 896 00:32:21,148 --> 00:32:22,606 ♪ ♪ 897 00:32:22,650 --> 00:32:25,776 - it's day four. Ready to get this thing done. 898 00:32:25,861 --> 00:32:27,653 So I just got done 899 00:32:27,738 --> 00:32:31,114 doing the profiling on my vajra-mushti. 900 00:32:31,158 --> 00:32:32,366 Feels pretty good. 901 00:32:32,451 --> 00:32:34,576 I'm gonna start doing fit up on the handle. 902 00:32:34,662 --> 00:32:36,787 ♪ ♪ 903 00:32:36,872 --> 00:32:38,121 I'm feeling great. 904 00:32:38,165 --> 00:32:41,625 At the end day, I used every minute that I had. 905 00:32:41,669 --> 00:32:43,961 There's definitely some finishing touches 906 00:32:44,004 --> 00:32:46,296 that I didn't get to that I wish I had-- 907 00:32:46,382 --> 00:32:48,006 mainly the handle. 908 00:32:48,092 --> 00:32:50,133 I'm hoping that there's not, you know, 909 00:32:50,219 --> 00:32:52,594 major hot spots around the knuckles or anything like that. 910 00:32:52,680 --> 00:32:55,263 It can look like crap, 911 00:32:55,349 --> 00:32:57,849 but as long as it feels comfortable in your hand, 912 00:32:57,935 --> 00:32:59,351 you know, that's fine. 913 00:32:59,436 --> 00:33:00,811 I feel good. 914 00:33:00,854 --> 00:33:03,647 I mean, I definitely did the best that I could. 915 00:33:03,691 --> 00:33:06,441 ♪ ♪ 916 00:33:06,527 --> 00:33:08,318 - final day, day four. 917 00:33:08,362 --> 00:33:09,987 I can't wait to get this thing all finished up 918 00:33:10,072 --> 00:33:11,279 and get it out the door. 919 00:33:11,365 --> 00:33:13,448 Start the day out fitting all the blades, 920 00:33:13,534 --> 00:33:14,825 gluing everything up. 921 00:33:14,868 --> 00:33:16,368 This thing's sweet, 922 00:33:16,453 --> 00:33:18,787 and it feels nice, too. 923 00:33:18,872 --> 00:33:20,580 The handle's coming out awesome. 924 00:33:20,666 --> 00:33:22,416 Exactly how I pictured it in my head. 925 00:33:22,501 --> 00:33:24,835 Now I just got to put the finishing touches on it. 926 00:33:24,920 --> 00:33:27,004 Having my wife pop in now and then 927 00:33:27,047 --> 00:33:28,338 is definitely motivation. 928 00:33:28,382 --> 00:33:29,464 - Hey, babe. 929 00:33:29,550 --> 00:33:30,966 - Hey. - I got the diamonds. 930 00:33:31,010 --> 00:33:32,718 - Sweet. - [chuckles] 931 00:33:32,803 --> 00:33:34,469 - I thought it would really make the handle pop 932 00:33:34,555 --> 00:33:36,888 if I could set these four diamonds in it. 933 00:33:36,974 --> 00:33:38,306 Day four in the books. 934 00:33:38,392 --> 00:33:40,058 It's been a lot of fun 935 00:33:40,144 --> 00:33:42,477 and can't wait to see this thing go through the testing, 936 00:33:42,563 --> 00:33:45,022 and hopefully I come out on top. 937 00:33:45,065 --> 00:33:48,025 [dramatic music] 938 00:33:48,068 --> 00:33:51,695 ♪ ♪ 939 00:33:51,780 --> 00:33:53,196 - guys, welcome back to the forge. 940 00:33:53,282 --> 00:33:54,531 You have had four days 941 00:33:54,575 --> 00:33:56,533 to work on your renditions of the vajra-mushti. 942 00:33:56,618 --> 00:33:58,201 Kyle, tell us about your work. 943 00:33:58,245 --> 00:34:00,537 - The blades are 1084 carbon steel 944 00:34:00,581 --> 00:34:01,663 with an acid etch. 945 00:34:01,749 --> 00:34:03,248 Handle's solid copper. 946 00:34:03,333 --> 00:34:04,875 I put forced patina on it 947 00:34:04,918 --> 00:34:08,420 and inlaid four certified diamonds into the handle. 948 00:34:08,505 --> 00:34:09,713 Do we get to keep them afterward? 949 00:34:09,757 --> 00:34:10,881 [laughter] 950 00:34:10,924 --> 00:34:12,883 very nice. Ben, how about yours? 951 00:34:12,926 --> 00:34:15,761 - The top and the bottom blade 952 00:34:15,846 --> 00:34:18,221 are 84 layers of 15n20 953 00:34:18,265 --> 00:34:19,723 and 1095. 954 00:34:19,767 --> 00:34:21,850 And then my knuckle blade is w1. 955 00:34:21,935 --> 00:34:23,852 My handle construction is all brass. 956 00:34:23,937 --> 00:34:26,188 - Well, only one of you guys will be leaving here 957 00:34:26,273 --> 00:34:28,023 as the champion of "forged in fire" 958 00:34:28,108 --> 00:34:29,816 with a check for $10,000, 959 00:34:29,902 --> 00:34:31,860 and we've got figure that out through a couple tests. 960 00:34:31,945 --> 00:34:34,404 We've got a sharpness test, a strength test, 961 00:34:34,448 --> 00:34:36,907 but up first, the infamous keal test 962 00:34:36,950 --> 00:34:38,575 with doug marcaida. 963 00:34:38,619 --> 00:34:40,243 ♪ ♪ 964 00:34:40,287 --> 00:34:43,121 bladesmiths, welcome to the keal test. 965 00:34:43,207 --> 00:34:46,041 To find out what kind of lethal damage your weapon will do, 966 00:34:46,085 --> 00:34:48,877 I will take your weapon and deliver multiple lethal blows 967 00:34:48,962 --> 00:34:50,712 on this ballistics dummy. 968 00:34:50,798 --> 00:34:51,755 Kyle, you're up first. You ready? 969 00:34:51,840 --> 00:34:52,756 - Oh, yeah. 970 00:34:52,841 --> 00:34:54,091 When I first saw the weapon, 971 00:34:54,134 --> 00:34:55,634 I was a little intimidated by it, 972 00:34:55,719 --> 00:34:57,511 but I kind of have the ability 973 00:34:57,596 --> 00:34:59,554 to, like, picture something in my head 974 00:34:59,640 --> 00:35:01,598 and make it come to life-- that's exactly what I did. 975 00:35:01,642 --> 00:35:04,101 The only fears that I have coming into it 976 00:35:04,186 --> 00:35:06,770 are the judges not liking the design 977 00:35:06,814 --> 00:35:08,438 that I put on the handle. 978 00:35:08,524 --> 00:35:11,441 [rock music] 979 00:35:11,485 --> 00:35:18,573 ♪ ♪ 980 00:35:26,667 --> 00:35:29,000 - wow. - [sighs] 981 00:35:29,086 --> 00:35:31,128 - all right, kyle, let's talk about your weapon here. 982 00:35:31,171 --> 00:35:32,587 I was worried about the finger welds 983 00:35:32,673 --> 00:35:34,798 that you had there, that they would be an issue, 984 00:35:34,842 --> 00:35:36,341 especially when I'm punching. 985 00:35:36,426 --> 00:35:37,634 No issues there. 986 00:35:37,719 --> 00:35:40,095 I like the fact that as it gets slippery, 987 00:35:40,180 --> 00:35:42,347 it gave me a very good grip. 988 00:35:42,432 --> 00:35:45,100 Overall, it is a beautiful piece, 989 00:35:45,185 --> 00:35:47,144 and your weapon will keal. 990 00:35:47,229 --> 00:35:48,270 - Oh, yeah. 991 00:35:48,355 --> 00:35:49,312 - All right, ben, your turn, sir. 992 00:35:49,398 --> 00:35:50,814 Are you ready? - I'm ready. 993 00:35:50,899 --> 00:35:51,982 - Let's do this. 994 00:35:52,025 --> 00:35:58,989 ♪ ♪ 995 00:36:10,544 --> 00:36:13,628 all right, ben, let's talk about your weapon here. 996 00:36:13,714 --> 00:36:15,630 The edges are very sharp, 997 00:36:15,716 --> 00:36:18,175 but there some sharp edges 998 00:36:18,218 --> 00:36:19,384 that you have in here. 999 00:36:19,469 --> 00:36:22,304 Every movement started to give me a little bruise 1000 00:36:22,389 --> 00:36:24,097 and cut off some skin right there. 1001 00:36:24,183 --> 00:36:26,308 But in terms of 1002 00:36:26,393 --> 00:36:28,518 what this weapon will do, 1003 00:36:28,604 --> 00:36:29,853 it will keal... 1004 00:36:29,938 --> 00:36:31,354 - Thanks, doug. - My hand. 1005 00:36:31,440 --> 00:36:33,398 - [laughs] 1006 00:36:33,483 --> 00:36:35,984 - all right, bladesmiths, welcome to the strength test. 1007 00:36:36,069 --> 00:36:38,528 To test the strength and durability 1008 00:36:38,572 --> 00:36:41,198 of your vajra-mushtis, as well as their overall construction, 1009 00:36:41,241 --> 00:36:43,074 I'll be stabbing and punching 1010 00:36:43,160 --> 00:36:44,534 into this sheet metal and chain. 1011 00:36:44,578 --> 00:36:46,286 Kyle, you're up first. You ready for this? 1012 00:36:46,371 --> 00:36:47,370 - Yep. 1013 00:36:47,414 --> 00:36:54,377 ♪ ♪ 1014 00:37:06,225 --> 00:37:07,766 [dramatic music] 1015 00:37:07,851 --> 00:37:10,018 - all right, kyle, in this strength test, 1016 00:37:10,103 --> 00:37:12,062 your two long blades held up great. 1017 00:37:12,147 --> 00:37:14,564 The center blade here took some chipping on that chain. 1018 00:37:14,650 --> 00:37:16,566 I'm looking at the grain in there, 1019 00:37:16,610 --> 00:37:17,734 and it's pretty big. 1020 00:37:17,819 --> 00:37:19,778 I would've liked to have seen that refined. 1021 00:37:19,863 --> 00:37:21,780 But in general, these two blades held up well. 1022 00:37:21,865 --> 00:37:23,907 Nice job. - Awesome, thanks, ben. 1023 00:37:23,951 --> 00:37:25,909 - All right, ben, you're up. You ready for this? 1024 00:37:25,953 --> 00:37:27,118 - Sure am. 1025 00:37:27,204 --> 00:37:29,204 I'm definitely feeling like kyle's ahead. 1026 00:37:29,248 --> 00:37:30,580 I know that my handle 1027 00:37:30,666 --> 00:37:33,416 is causing some pain on the judges' hands, 1028 00:37:33,460 --> 00:37:34,918 and that's just weighing on my mind. 1029 00:37:35,003 --> 00:37:36,253 I know that's big for them, 1030 00:37:36,296 --> 00:37:38,088 and it could potentially send me home. 1031 00:37:38,131 --> 00:37:39,714 I'm super nervous 1032 00:37:39,800 --> 00:37:42,926 because I totally don't know what's gonna happen. 1033 00:37:42,970 --> 00:37:46,388 ♪ ♪ 1034 00:37:49,226 --> 00:37:49,933 [rock music] 1035 00:37:49,977 --> 00:37:56,940 ♪ ♪ 1036 00:38:09,037 --> 00:38:10,245 - all right, ben, well, 1037 00:38:10,330 --> 00:38:11,913 the first thing I feel when I pick this weapon up 1038 00:38:11,999 --> 00:38:13,248 is its sheer mass. 1039 00:38:13,333 --> 00:38:14,916 I mean, it's a heavy, heavy weapon. 1040 00:38:15,002 --> 00:38:16,751 That did you some justice in the strength test. 1041 00:38:16,837 --> 00:38:18,003 The only thing I could see 1042 00:38:18,088 --> 00:38:20,130 is a little bit of glinting on the lower blade. 1043 00:38:20,215 --> 00:38:22,090 But the middle blade, 1044 00:38:22,175 --> 00:38:24,968 it took a pretty major deflection right here. 1045 00:38:25,053 --> 00:38:26,845 It kind of cracked. 1046 00:38:26,930 --> 00:38:29,639 One more little hit here, and that would just come off. 1047 00:38:29,683 --> 00:38:32,434 The main thing working against you on this blade 1048 00:38:32,519 --> 00:38:35,103 is the rough inner surface. 1049 00:38:35,188 --> 00:38:37,355 I couldn't really find a real comfortable way 1050 00:38:37,441 --> 00:38:39,649 of getting this finger out of harm's way. 1051 00:38:39,735 --> 00:38:42,193 But after the strength test, it's all in one piece. 1052 00:38:42,279 --> 00:38:43,987 Nice job. - Thank you. 1053 00:38:44,031 --> 00:38:45,989 ♪ ♪ 1054 00:38:46,033 --> 00:38:48,825 - all right, bladesmiths, we know your weapons can keal, 1055 00:38:48,910 --> 00:38:50,327 and we know they are strong. 1056 00:38:50,412 --> 00:38:52,662 Now it's time to find out just how sharp they are. 1057 00:38:52,748 --> 00:38:54,122 To find out, I'll take your weapons 1058 00:38:54,207 --> 00:38:56,166 and deliver some stabs and slices 1059 00:38:56,251 --> 00:38:58,168 on these spice bags. 1060 00:38:58,253 --> 00:38:59,961 Kyle, you're up first. You ready for this? 1061 00:39:00,047 --> 00:39:01,296 - Yep. - Let's do this. 1062 00:39:01,381 --> 00:39:08,511 ♪ ♪ 1063 00:39:22,402 --> 00:39:24,277 all right, kyle, let's talk about your weapon. 1064 00:39:24,363 --> 00:39:26,863 It is comfortable. It's a good fit on my hand. 1065 00:39:26,907 --> 00:39:29,240 It's got a pointy-enough tip over there, 1066 00:39:29,326 --> 00:39:31,826 but with that one piece where you're missing some edges, 1067 00:39:31,912 --> 00:39:33,411 it was more of a jagged cut. 1068 00:39:33,497 --> 00:39:35,663 When it came to stabbing and slashing 1069 00:39:35,749 --> 00:39:39,501 on both weapons on each end, it will cut. 1070 00:39:39,544 --> 00:39:41,711 Good job. - Thank you, doug. 1071 00:39:41,755 --> 00:39:43,088 - Ben, your turn, sir. You ready? 1072 00:39:43,173 --> 00:39:45,382 - Ready, let's go. - Let's do it. 1073 00:39:45,425 --> 00:39:48,385 [dramatic music] 1074 00:39:48,428 --> 00:39:55,392 ♪ ♪ 1075 00:40:04,861 --> 00:40:06,236 all right, ben, let's talk about your weapon. 1076 00:40:06,321 --> 00:40:08,238 The weight that you have here 1077 00:40:08,323 --> 00:40:11,074 back up the cut because you have very sharp edges, 1078 00:40:11,159 --> 00:40:13,243 and the cuts are very deep, 1079 00:40:13,286 --> 00:40:14,369 but my hand, when I'm making impacts, 1080 00:40:14,454 --> 00:40:16,913 still rubs on the inside of your handle. 1081 00:40:16,998 --> 00:40:20,583 But other than that, sir, your beast, it will cut. 1082 00:40:20,627 --> 00:40:22,085 - Thanks, doug. 1083 00:40:22,129 --> 00:40:24,921 ♪ ♪ 1084 00:40:24,965 --> 00:40:26,464 - all right, guys, 1085 00:40:26,550 --> 00:40:28,716 you guys both came through with unbelievable pieces of work 1086 00:40:28,802 --> 00:40:30,051 verging on art, 1087 00:40:30,137 --> 00:40:32,053 and they performed almost equally on all the tests, 1088 00:40:32,097 --> 00:40:34,055 but we do have to make a decision. 1089 00:40:34,099 --> 00:40:35,765 The judges are gonna have to confer 1090 00:40:35,809 --> 00:40:36,808 and go over those fine details. 1091 00:40:36,893 --> 00:40:38,101 While they do that, 1092 00:40:38,145 --> 00:40:39,602 I'm gonna ask you to step off the forge floor. 1093 00:40:39,646 --> 00:40:40,895 ♪ ♪ 1094 00:40:40,939 --> 00:40:42,439 - after seeing ben's weapon, 1095 00:40:42,482 --> 00:40:44,399 I felt like we were pretty evenly matched, 1096 00:40:44,443 --> 00:40:45,692 but this is "forged in fire," 1097 00:40:45,777 --> 00:40:47,610 and you never know what way it's gonna go. 1098 00:40:47,654 --> 00:40:48,945 - All right, guys. What do you think? 1099 00:40:49,030 --> 00:40:50,113 It seems pretty close to me. 1100 00:40:50,157 --> 00:40:51,990 - Looking at the two weapons, 1101 00:40:52,075 --> 00:40:54,117 I think kyle's blade is strong. 1102 00:40:54,161 --> 00:40:55,618 It took some chipping in the strength test, 1103 00:40:55,662 --> 00:40:57,412 but then if you look at ben's blade, 1104 00:40:57,497 --> 00:40:59,122 it also took some chipping in the strength test. 1105 00:40:59,207 --> 00:41:01,124 - Both blades definitely can keal, 1106 00:41:01,209 --> 00:41:02,792 and both blades are definitely sharp, 1107 00:41:02,836 --> 00:41:05,086 but one weapon is a lot more comfortable 1108 00:41:05,130 --> 00:41:06,546 to wield and control. 1109 00:41:06,631 --> 00:41:08,923 A weapon should only hurt the enemy, 1110 00:41:09,009 --> 00:41:10,300 not the end user. 1111 00:41:10,385 --> 00:41:11,801 - Okay, so you guys are in agreement? 1112 00:41:11,845 --> 00:41:14,137 All: Yeah. - We'll call them back in. 1113 00:41:14,181 --> 00:41:20,143 ♪ ♪ 1114 00:41:20,187 --> 00:41:21,853 all right, guys. It was very, very close. 1115 00:41:21,938 --> 00:41:23,605 You guys both did a phenomenal job. 1116 00:41:23,690 --> 00:41:25,940 Unfortunately, we can only send one of you guys home 1117 00:41:25,984 --> 00:41:27,859 with the title of "forged in fire" champion 1118 00:41:27,944 --> 00:41:29,819 and a check for $10,000, 1119 00:41:29,863 --> 00:41:31,821 and our champion today is... 1120 00:41:31,865 --> 00:41:33,781 ♪ ♪ 1121 00:41:33,867 --> 00:41:35,158 kyle. Congratulations. 1122 00:41:35,202 --> 00:41:36,493 Ben, unfortunately, 1123 00:41:36,536 --> 00:41:38,161 you're not walking home the champion today. 1124 00:41:38,205 --> 00:41:39,746 Doug's gonna tell you why. 1125 00:41:39,831 --> 00:41:42,332 - Ben, I commend you on building a very unique weapon, 1126 00:41:42,375 --> 00:41:44,042 but only your handle 1127 00:41:44,127 --> 00:41:47,128 affected both of us when we were testing it, 1128 00:41:47,214 --> 00:41:48,630 and for that reason, we're sending you home. 1129 00:41:48,715 --> 00:41:50,673 - Okay. Totally understand. 1130 00:41:50,759 --> 00:41:52,550 - All right, ben, you obviously showed you had what it takes 1131 00:41:52,636 --> 00:41:54,677 to be in the forge and to compete with some of the best, 1132 00:41:54,763 --> 00:41:56,513 but, unfortunately, the time has come. 1133 00:41:56,556 --> 00:41:58,014 I'm gonna have to ask you to leave the forge floor. 1134 00:41:58,058 --> 00:41:59,516 - All right. Thank you, guys. 1135 00:41:59,601 --> 00:42:01,309 This was awesome, for sure. 1136 00:42:01,394 --> 00:42:02,644 - Good job. - Kyle, amazing job. 1137 00:42:02,729 --> 00:42:04,312 Honestly, I feel great. 1138 00:42:04,397 --> 00:42:06,523 I mean, it was an amazing experience. 1139 00:42:06,566 --> 00:42:07,899 I'm super happy for kyle. 1140 00:42:07,984 --> 00:42:10,485 I had a feeling that handle was gonna get me, 1141 00:42:10,529 --> 00:42:11,819 but I busted my butt, 1142 00:42:11,905 --> 00:42:14,322 and honestly did the best that I could, 1143 00:42:14,366 --> 00:42:17,033 so I don't have any regrets. 1144 00:42:17,118 --> 00:42:18,826 - Well, kyle, congratulations. 1145 00:42:18,912 --> 00:42:20,537 You'll be leaving here with the title 1146 00:42:20,622 --> 00:42:23,498 "forged in fire" champion and a check for $10,000. 1147 00:42:23,542 --> 00:42:24,707 Congratulations. - Thank you. 1148 00:42:24,793 --> 00:42:25,875 [applause] 1149 00:42:25,961 --> 00:42:27,502 my wife's gonna be super pumped 1150 00:42:27,587 --> 00:42:30,046 when I tell her that I'm the next "forged in fire" champion. 1151 00:42:30,131 --> 00:42:32,674 - What are you gonna do with that cash, man? 1152 00:42:32,759 --> 00:42:33,841 - My wife and I are probably gonna use it 1153 00:42:33,885 --> 00:42:35,218 for a down payment on a house. 1154 00:42:35,262 --> 00:42:36,636 - That's absolutely fantastic. - Nice, nice. 1155 00:42:36,721 --> 00:42:37,762 - Cool. 1156 00:42:37,847 --> 00:42:39,222 - 18 months ago, 1157 00:42:39,266 --> 00:42:41,140 I would've never imagined being here today. 1158 00:42:41,226 --> 00:42:43,268 Hell, yeah. I'm "forged in fire" champion. 1159 00:42:43,353 --> 00:42:45,186 [laughs] 1160 00:42:45,272 --> 00:42:50,233 ♪ ♪