1 00:00:05,047 --> 00:00:07,965 [heavy rock music] 2 00:00:08,050 --> 00:00:14,680 ♪ ♪ 3 00:00:15,725 --> 00:00:17,433 - I'm beau gieson, 52. 4 00:00:17,518 --> 00:00:19,309 I love to forge. 5 00:00:19,395 --> 00:00:21,729 It's just molding metal to whatever you want it to be. 6 00:00:21,814 --> 00:00:23,522 The artistic side of it-- 7 00:00:23,566 --> 00:00:25,899 you can just do anything when you can move metal. 8 00:00:25,985 --> 00:00:29,361 ♪ ♪ 9 00:00:29,405 --> 00:00:32,322 - my name is starlin moran. I'm 42 years old. 10 00:00:32,408 --> 00:00:33,824 ♪ ♪ 11 00:00:33,909 --> 00:00:36,285 I'm fortunate that my fiancée is super supportive. 12 00:00:36,370 --> 00:00:40,414 My teenager, she's a little more unimpressed with me. 13 00:00:40,499 --> 00:00:44,001 She said I better not get kicked out on the first round. 14 00:00:44,086 --> 00:00:45,461 ♪ ♪ 15 00:00:45,546 --> 00:00:46,628 my name's kevin adams, 16 00:00:46,714 --> 00:00:47,796 and I am a technical instructor 17 00:00:47,882 --> 00:00:48,797 for the united states army, 18 00:00:48,883 --> 00:00:50,549 and I am a part-time bladesmith. 19 00:00:50,634 --> 00:00:52,134 My grandfather and my father 20 00:00:52,219 --> 00:00:53,677 worked in the same steel mill together. 21 00:00:53,763 --> 00:00:55,596 So their influence enabled me 22 00:00:55,681 --> 00:00:58,515 to be able to pick up the trade fairly quickly. 23 00:00:58,601 --> 00:01:00,100 - My name is aric fontaine, 24 00:01:00,186 --> 00:01:03,771 and I have been bladesmithing now for almost 10 years. 25 00:01:03,856 --> 00:01:07,691 I stay with it because it's a comfort place for me. 26 00:01:07,777 --> 00:01:09,693 And just being able to create something, 27 00:01:09,779 --> 00:01:11,945 it's a really cool experience. 28 00:01:12,031 --> 00:01:13,864 ♪ ♪ 29 00:01:13,949 --> 00:01:16,366 - all right, bladesmiths. Welcome to the forge. 30 00:01:16,452 --> 00:01:18,368 You guys are here to compete and test yourselves 31 00:01:18,454 --> 00:01:20,537 in three intense rounds of forging competition. 32 00:01:20,623 --> 00:01:22,706 At the end of each round, you guys will present your work 33 00:01:22,750 --> 00:01:24,333 to our panel of expert judges. 34 00:01:24,418 --> 00:01:25,709 Those judges today are 35 00:01:25,795 --> 00:01:28,170 abs mastersmith j. Neilson, 36 00:01:28,255 --> 00:01:31,423 historic weapons re-creation specialist dave baker, 37 00:01:31,509 --> 00:01:33,801 and edge-weapon specialist and kali martial artist 38 00:01:33,886 --> 00:01:35,385 doug marcaida. 39 00:01:35,471 --> 00:01:38,180 Only one of you will be leaving here with the coveted title 40 00:01:38,265 --> 00:01:42,518 of "forged in fire" champion and a check for $10,000. 41 00:01:42,603 --> 00:01:44,978 So let's get into it. 42 00:01:45,064 --> 00:01:50,442 ♪ ♪ 43 00:01:50,528 --> 00:01:52,236 as I'm sure you've already guessed, 44 00:01:52,321 --> 00:01:54,113 you guys will be salvaging your metals 45 00:01:54,198 --> 00:01:56,657 from this here burned-out suv. 46 00:01:56,742 --> 00:01:58,283 Most bladesmiths will probably go 47 00:01:58,369 --> 00:01:59,618 straight for the leaf springs, 48 00:01:59,662 --> 00:02:01,578 but if you noticed, there's none available. 49 00:02:01,664 --> 00:02:03,288 So you guys will have to be creative 50 00:02:03,374 --> 00:02:05,124 in sourcing your materials for your blades. 51 00:02:05,167 --> 00:02:07,042 All I ask is that you follow these parameters. 52 00:02:07,128 --> 00:02:08,502 Your blades, at the end of round one, 53 00:02:08,587 --> 00:02:10,462 need to be between 12 and 14 inches 54 00:02:10,548 --> 00:02:12,798 from tip to where the cutting edge ends, 55 00:02:12,883 --> 00:02:14,174 in a straight line. 56 00:02:14,260 --> 00:02:16,260 - My brothers and my uncle and I 57 00:02:16,303 --> 00:02:17,886 have always been backyard mechanics. 58 00:02:17,972 --> 00:02:21,056 But I can't tell you what things are made out of. 59 00:02:21,142 --> 00:02:25,144 So I have to get creative and find hardenable steel. 60 00:02:25,229 --> 00:02:26,603 - Now, in round two of the competition, 61 00:02:26,689 --> 00:02:28,397 you guy will add handles to your blades, 62 00:02:28,482 --> 00:02:30,399 turning them into fully functioning weapons, 63 00:02:30,484 --> 00:02:31,817 at which point, 64 00:02:31,902 --> 00:02:33,610 we will be testing them for strength and durability 65 00:02:33,696 --> 00:02:35,112 in a brutal tailgate chop 66 00:02:35,197 --> 00:02:38,115 and for sharpness in a fuel-hose slice. 67 00:02:38,200 --> 00:02:39,533 Keep your eyes on the clock, 68 00:02:39,618 --> 00:02:41,201 because you guys will only have three hours. 69 00:02:41,287 --> 00:02:43,620 And that time...Starts now. 70 00:02:43,706 --> 00:02:45,455 ♪ ♪ 71 00:02:45,541 --> 00:02:47,875 - off to the races, once again! 72 00:02:47,960 --> 00:02:49,626 ♪ ♪ 73 00:02:49,712 --> 00:02:51,044 - I don't know jack about cars. 74 00:02:51,130 --> 00:02:52,796 - That why your car's in the shop? 75 00:02:52,882 --> 00:02:54,882 - That's why I dumped three grand on my car yesterday. 76 00:02:54,967 --> 00:02:57,092 - [groans] - you going for that? 77 00:02:57,178 --> 00:02:58,552 - Yup. 78 00:02:58,637 --> 00:03:00,095 - We don't have leaf springs in this suv. 79 00:03:00,181 --> 00:03:02,014 So what are you thinking they're gonna be going for? 80 00:03:02,099 --> 00:03:03,807 - Any kind of springs that are in there. 81 00:03:03,893 --> 00:03:06,226 You got different rods. There's bearings you can use. 82 00:03:06,312 --> 00:03:08,353 - It's medium-carbon steel. 83 00:03:08,439 --> 00:03:10,063 So it's more than good enough to make a knife 84 00:03:10,149 --> 00:03:11,815 that'll hold up in our test. 85 00:03:11,901 --> 00:03:13,650 - There's no leaf springs. 86 00:03:13,736 --> 00:03:15,152 I don't know what I'm gonna do. 87 00:03:15,237 --> 00:03:17,070 I'm gonna get under there and start hackin' away. 88 00:03:17,156 --> 00:03:19,740 I go right for the spring on the back tire... 89 00:03:19,825 --> 00:03:21,450 ♪ ♪ 90 00:03:21,535 --> 00:03:23,994 toss it in the fire, and then I start thinking, 91 00:03:24,079 --> 00:03:25,829 "maybe that's not enough steel?" 92 00:03:25,915 --> 00:03:28,040 I'm gonna go and see what else I can find. 93 00:03:28,125 --> 00:03:29,666 Let's get some more steel. 94 00:03:29,752 --> 00:03:33,045 I crawl down there, and there's some big round bar stock. 95 00:03:33,130 --> 00:03:35,339 - Well, if you get into the front suspension over here, 96 00:03:35,424 --> 00:03:37,507 there are a couple of pieces of round stock. 97 00:03:37,593 --> 00:03:39,509 Heat that up and put it in the press... 98 00:03:39,595 --> 00:03:40,886 - You'd think that'd be the easiest way? 99 00:03:40,930 --> 00:03:42,262 - I think so, yeah. 100 00:03:42,348 --> 00:03:44,473 - I don't need this small coil anymore. 101 00:03:44,558 --> 00:03:46,308 I think I should be okay. 102 00:03:46,393 --> 00:03:47,476 I'm gonna heat this up, 103 00:03:47,561 --> 00:03:49,519 and I'm gonna try out that press. 104 00:03:49,605 --> 00:03:53,482 ♪ ♪ 105 00:03:53,567 --> 00:03:55,317 - that's the piece I want. 106 00:03:55,402 --> 00:03:57,027 My son used to race motocross, 107 00:03:57,112 --> 00:03:59,446 and I was his mechanic that entire time. 108 00:03:59,531 --> 00:04:01,531 So I know where there's good steel. 109 00:04:01,617 --> 00:04:03,408 ♪ ♪ 110 00:04:03,494 --> 00:04:05,953 the torsion bar-- it's good, strong steel. 111 00:04:06,038 --> 00:04:07,955 [saw whirring] 112 00:04:08,040 --> 00:04:09,623 [bleep] 113 00:04:09,708 --> 00:04:11,541 - whatever he was doing, it's gotta be hard, 114 00:04:11,627 --> 00:04:14,461 'cause his angle grinder is messed up. 115 00:04:14,546 --> 00:04:16,630 - I'm not trying to rush myself. 116 00:04:16,715 --> 00:04:18,257 Don't worry about everybody else. 117 00:04:18,342 --> 00:04:19,341 Do your own thing. 118 00:04:19,426 --> 00:04:21,218 This is a lot. 119 00:04:21,303 --> 00:04:23,887 - I have no experience harvesting steel 120 00:04:23,973 --> 00:04:25,430 from something like this. 121 00:04:25,516 --> 00:04:28,475 ♪ I'm already freaking out ♪ 122 00:04:28,560 --> 00:04:29,935 the shackles, 123 00:04:29,979 --> 00:04:32,896 those have to be made out of some hardenable steel 124 00:04:32,982 --> 00:04:35,148 because they can tow cars with it. 125 00:04:35,234 --> 00:04:36,441 ♪ ♪ 126 00:04:36,527 --> 00:04:37,776 - starlin's over on the grinder. 127 00:04:37,861 --> 00:04:39,945 He's got that-- what looked like the tow hitch, 128 00:04:40,030 --> 00:04:41,655 but it's not sparking at all. 129 00:04:41,740 --> 00:04:44,825 - It's a sign that that stuff's probably very tough. 130 00:04:44,910 --> 00:04:46,785 Doesn't necessarily mean it's hardenable, though. 131 00:04:46,829 --> 00:04:48,578 [whirring] 132 00:04:48,664 --> 00:04:50,956 - I'm grinding away and I'm not seeing sparks. 133 00:04:51,000 --> 00:04:54,251 But I think it's because of the paint on it. 134 00:04:54,295 --> 00:04:55,585 So I think I can still use it. 135 00:04:55,671 --> 00:04:56,878 ♪ ♪ 136 00:04:56,964 --> 00:04:59,756 calm down. Calm down. 137 00:04:59,842 --> 00:05:01,008 ♪ ♪ 138 00:05:01,093 --> 00:05:03,677 - I have made knives out of car parts, before. 139 00:05:03,762 --> 00:05:06,763 So I'm immediately looking for springs 140 00:05:06,849 --> 00:05:09,182 because I know those are gonna be 5160. 141 00:05:09,268 --> 00:05:11,059 - He went straight for that piece. 142 00:05:11,145 --> 00:05:12,311 He's got in his mind that 143 00:05:12,396 --> 00:05:14,271 that's already a hardenable piece of steel. 144 00:05:14,356 --> 00:05:17,357 - I got coil springs, and I am elated. 145 00:05:17,443 --> 00:05:18,859 [saw buzzing] 146 00:05:18,944 --> 00:05:22,612 so now I need to get the coil spring straight. 147 00:05:22,698 --> 00:05:25,032 - He got it nice and hot before he went to straighten it out. 148 00:05:25,117 --> 00:05:26,575 - Yeah. - That was smart. 149 00:05:26,660 --> 00:05:30,829 - My next order of business is to go over to big blu 150 00:05:30,914 --> 00:05:33,206 to widen it and flatten it. 151 00:05:33,292 --> 00:05:34,583 ♪ ♪ 152 00:05:34,668 --> 00:05:35,792 - all right, bladesmiths. 153 00:05:35,878 --> 00:05:38,503 You guys have 30 minutes off the clock. 154 00:05:38,547 --> 00:05:39,921 - Whoo! 155 00:05:40,007 --> 00:05:41,631 - My plan for the round is 156 00:05:41,717 --> 00:05:44,217 to get this thing drawn out with the press. 157 00:05:44,303 --> 00:05:46,636 - That looks like it's maybe 5/8's thick. 158 00:05:46,722 --> 00:05:47,929 - Okay. 159 00:05:48,015 --> 00:05:49,556 - Now, to try to draw that out wide enough 160 00:05:49,641 --> 00:05:52,267 to make a decent blade is gonna be tough. 161 00:05:52,353 --> 00:05:54,311 What he's not doing is fullering it, 162 00:05:54,396 --> 00:05:55,812 making that material wider. 163 00:05:55,898 --> 00:05:58,482 As it is, he's just making it longer. 164 00:05:58,567 --> 00:05:59,691 ♪ ♪ 165 00:05:59,777 --> 00:06:01,401 - my blade's very thick. 166 00:06:01,487 --> 00:06:02,736 ♪ ♪ 167 00:06:02,821 --> 00:06:04,863 the judges tend to not like heavy blades. 168 00:06:04,948 --> 00:06:08,658 So all I'm doing right now is just hogging off material. 169 00:06:08,744 --> 00:06:10,077 All right. 170 00:06:10,162 --> 00:06:12,245 ♪ ♪ 171 00:06:12,331 --> 00:06:14,873 - [laughs] out here, but in here... 172 00:06:14,958 --> 00:06:16,500 [laughs frantically] 173 00:06:16,585 --> 00:06:18,293 - I got my steel in the forge. 174 00:06:18,379 --> 00:06:19,753 Everything's looking good. 175 00:06:19,838 --> 00:06:20,754 That's all right. 176 00:06:20,839 --> 00:06:22,255 I gotta widen the blade 177 00:06:22,341 --> 00:06:23,757 and I'm gonna fine-tune my handle. 178 00:06:23,842 --> 00:06:26,051 - Yeah, so, it looks like kevin is making 179 00:06:26,136 --> 00:06:28,345 a integral bolster and a full-tang chopper. 180 00:06:28,430 --> 00:06:29,679 That's cool. 181 00:06:29,765 --> 00:06:32,015 - I make bolsters on many of my blades, 182 00:06:32,101 --> 00:06:34,810 and that is a good, really strong point in the blade. 183 00:06:34,895 --> 00:06:36,853 So it can handle a lot of abuse. 184 00:06:36,939 --> 00:06:38,688 ♪ ♪ 185 00:06:38,774 --> 00:06:41,733 - right now I'm trying to get my blade to length, 186 00:06:41,777 --> 00:06:42,901 but the challenge that I'm having 187 00:06:42,986 --> 00:06:44,069 with this piece of steel 188 00:06:44,154 --> 00:06:45,904 is straightening it out. 189 00:06:45,989 --> 00:06:47,531 It will bend to my will! 190 00:06:47,616 --> 00:06:48,615 ♪ ♪ 191 00:06:48,700 --> 00:06:50,283 - starlin's having a lot of trouble 192 00:06:50,369 --> 00:06:51,576 getting that thing flattened out. 193 00:06:51,662 --> 00:06:53,537 - The press is giving me problems. 194 00:06:53,622 --> 00:06:57,165 So I put it on the anvil to try to hammer it out. 195 00:06:57,251 --> 00:06:58,500 All of the sudden... 196 00:06:58,585 --> 00:07:00,752 [dramatic music] 197 00:07:00,796 --> 00:07:01,878 it breaks. 198 00:07:01,964 --> 00:07:03,171 Ah, crap. 199 00:07:03,257 --> 00:07:06,049 - Starlin just broke his spring. 200 00:07:06,135 --> 00:07:07,759 - So if that ring is cast iron, 201 00:07:07,845 --> 00:07:10,345 if you get it too hot or work it too cold, 202 00:07:10,431 --> 00:07:11,930 it's just gonna crumble. 203 00:07:12,015 --> 00:07:14,474 - I'm crushed. There's no other way to say it. 204 00:07:14,560 --> 00:07:15,892 Oh! 205 00:07:15,978 --> 00:07:18,353 - It looks like starlin broke his steel in half. 206 00:07:18,439 --> 00:07:19,438 So I'm gonna help out. 207 00:07:19,523 --> 00:07:22,107 You got a crack? - My piece just broke. 208 00:07:22,192 --> 00:07:25,444 - I got some coil under my forge, if you want. 209 00:07:25,487 --> 00:07:26,653 - Oh, thanks, man! 210 00:07:26,738 --> 00:07:27,821 [upbeat music] 211 00:07:27,906 --> 00:07:29,531 - I'm gonna give somebody a hand 212 00:07:29,616 --> 00:07:31,616 because I just think that's just part of the trade. 213 00:07:31,702 --> 00:07:33,410 This is how you work. 214 00:07:33,495 --> 00:07:35,203 - Starlin, so panicked right now, 215 00:07:35,289 --> 00:07:36,830 he didn't even look at it or think about it. 216 00:07:36,915 --> 00:07:38,206 He immediately said, "thank you," 217 00:07:38,292 --> 00:07:39,583 and threw it in the forge. 218 00:07:39,668 --> 00:07:42,711 - Beau, you're a gentleman and a scholar. 219 00:07:42,796 --> 00:07:44,754 I love you? [laughs] 220 00:07:44,840 --> 00:07:47,299 ♪ ♪ 221 00:07:47,384 --> 00:07:49,801 - I need to get the coil spring flattened out. 222 00:07:49,887 --> 00:07:54,598 So I'm over at big blu, and I put it in at a diagonal. 223 00:07:54,683 --> 00:07:56,475 So not only does it flatten it, 224 00:07:56,518 --> 00:07:59,227 but it also widens it at the same time. 225 00:07:59,313 --> 00:08:00,687 I'm feeling very good. 226 00:08:00,772 --> 00:08:02,814 My billet is almost to the point 227 00:08:02,900 --> 00:08:04,441 where I can start hand shaping it. 228 00:08:04,526 --> 00:08:06,776 ♪ ♪ 229 00:08:06,862 --> 00:08:09,779 - I can finally start my heat treat. 230 00:08:09,865 --> 00:08:11,698 - Beau's getting ready to quench. 231 00:08:11,783 --> 00:08:14,701 [dramatic music] - leave it down in there. 232 00:08:14,786 --> 00:08:16,161 ♪ ♪ 233 00:08:16,246 --> 00:08:19,206 - I grab a file. I ran it across the blade. 234 00:08:19,291 --> 00:08:20,290 ♪ ♪ 235 00:08:20,375 --> 00:08:21,875 [bleep] 236 00:08:21,960 --> 00:08:23,251 not hardened. 237 00:08:23,337 --> 00:08:24,211 [dramatic percussion] 238 00:08:24,296 --> 00:08:25,170 [bleep] 239 00:08:25,255 --> 00:08:26,546 my quench was off. 240 00:08:26,632 --> 00:08:29,090 - The file stuttered on beau's blade, 241 00:08:29,176 --> 00:08:31,176 so he's back in the forge again. 242 00:08:31,261 --> 00:08:33,720 - Gentlemen, there's one hour remaining! 243 00:08:33,805 --> 00:08:36,973 - So it looks like I'm gonna have to quench again. 244 00:08:37,059 --> 00:08:39,017 Lots of stuff can go wrong. 245 00:08:39,102 --> 00:08:40,685 You can get a crack in your blade. 246 00:08:40,771 --> 00:08:42,938 You can bend your blade and warp it. 247 00:08:43,023 --> 00:08:44,356 What the [bleep]? 248 00:08:44,441 --> 00:08:46,483 So I'm worried I'm gonna have to start all over. 249 00:08:46,568 --> 00:08:47,442 [dramatic percussion] 250 00:08:50,155 --> 00:08:52,197 it out a little hotter. 251 00:08:52,241 --> 00:08:53,823 ♪ ♪ 252 00:08:53,909 --> 00:08:55,367 [bleep]. - There we go. 253 00:08:55,410 --> 00:08:56,368 - Yeah, perfect. - Nice color. 254 00:08:56,411 --> 00:08:58,662 - That's the color you wanna see! 255 00:08:58,747 --> 00:09:00,372 [dramatic music] 256 00:09:00,415 --> 00:09:01,706 - whoo! 257 00:09:01,750 --> 00:09:03,833 ♪ ♪ 258 00:09:03,919 --> 00:09:06,378 I pull it out of the quench, I hit it with the file. 259 00:09:06,421 --> 00:09:07,921 ♪ ♪ 260 00:09:08,006 --> 00:09:09,005 okay. 261 00:09:09,091 --> 00:09:10,298 It's good to go. 262 00:09:10,384 --> 00:09:12,217 Thank god I'm finally done with that 263 00:09:12,302 --> 00:09:13,343 and I can get on the grinder 264 00:09:13,428 --> 00:09:14,511 and remove some of this material. 265 00:09:14,596 --> 00:09:18,056 ♪ ♪ 266 00:09:18,141 --> 00:09:20,725 - I have to grind in a good profile 267 00:09:20,769 --> 00:09:22,227 and get my handle ground in 268 00:09:22,312 --> 00:09:25,230 and get the bolster set for the blade. 269 00:09:25,315 --> 00:09:26,398 - I'll tell you, though, 270 00:09:26,483 --> 00:09:28,567 I do like the profile that kevin has. 271 00:09:28,610 --> 00:09:30,402 ♪ ♪ 272 00:09:30,487 --> 00:09:31,861 - I got into bladesmithing 273 00:09:31,947 --> 00:09:33,947 because my time in the military-- 274 00:09:34,032 --> 00:09:36,533 I also have to deal with ptsd. 275 00:09:36,618 --> 00:09:40,036 Bladesmithing allows you to be creative with your mind 276 00:09:40,122 --> 00:09:42,289 and to keep you focused. 277 00:09:42,374 --> 00:09:44,249 - Please work, please work, please work, please work. 278 00:09:44,293 --> 00:09:45,250 Please work. 279 00:09:45,294 --> 00:09:46,585 ♪ ♪ 280 00:09:46,670 --> 00:09:49,254 I finally get my second billet straightened. 281 00:09:49,298 --> 00:09:51,590 I have way too much. 282 00:09:51,675 --> 00:09:53,258 Just gotta be very careful. 283 00:09:53,302 --> 00:09:56,595 I just chop off the rest that I don't need. 284 00:09:56,638 --> 00:09:58,847 - What's starlin choppin' off at the chop saw? 285 00:09:58,932 --> 00:10:00,473 He didn't have a lot of metal to work with. 286 00:10:00,559 --> 00:10:04,769 - Starlin's only got...What? Maybe 9 inches of steel there? 287 00:10:04,855 --> 00:10:07,606 And his cutting edge needs to be at least 12 inches. 288 00:10:07,649 --> 00:10:09,441 - He needs every inch of that metal. 289 00:10:09,484 --> 00:10:11,735 ♪ ♪ 290 00:10:11,778 --> 00:10:13,236 - I'm shooting for a chopper, man. 291 00:10:13,322 --> 00:10:14,279 I love choppers, and, uh, 292 00:10:14,323 --> 00:10:16,281 based off the parameters, 293 00:10:16,325 --> 00:10:18,074 I don't have to have a point, which is perfect. 294 00:10:18,160 --> 00:10:19,492 ♪ ♪ 295 00:10:19,578 --> 00:10:21,286 it's starting to look like a blade. 296 00:10:21,330 --> 00:10:23,330 So I'm feeling really good. 297 00:10:23,415 --> 00:10:24,998 Yeah! 298 00:10:25,083 --> 00:10:27,125 - My blade is going very well. 299 00:10:27,210 --> 00:10:29,252 I'm finishing up at the grinder, 300 00:10:29,296 --> 00:10:31,004 and I'm ready for quenching. 301 00:10:31,089 --> 00:10:33,298 - That blade is screaming hot at the tip. 302 00:10:33,342 --> 00:10:36,259 ♪ ♪ 303 00:10:36,303 --> 00:10:37,802 - that's way too hot. 304 00:10:37,888 --> 00:10:39,429 - I think it came out quite well. 305 00:10:39,514 --> 00:10:42,265 ♪ ♪ 306 00:10:42,309 --> 00:10:44,100 - back to grinding, I guess. 307 00:10:44,186 --> 00:10:45,644 So I'm at the grinder, 308 00:10:45,687 --> 00:10:47,145 and I'm trying to clean this thing up. 309 00:10:47,189 --> 00:10:50,649 And then I realize this is just a rectangle of nothing. 310 00:10:50,692 --> 00:10:51,858 ♪ ♪ 311 00:10:51,943 --> 00:10:53,443 I'm gonna put a bend in the entire blade 312 00:10:53,487 --> 00:10:55,654 to give it a little more character 313 00:10:55,697 --> 00:10:58,448 and then I'm also gonna grind the tip. 314 00:10:58,533 --> 00:11:00,950 - So basically what beau's just done 315 00:11:00,994 --> 00:11:02,494 is undone his quench. 316 00:11:02,537 --> 00:11:05,246 - He's gonna have to redo it. Just wasted a lot of time. 317 00:11:05,332 --> 00:11:07,165 - A lot of time. 318 00:11:07,250 --> 00:11:09,542 - I'm gonna have to heat-treat for a third time, 319 00:11:09,628 --> 00:11:11,169 which is a big risk. 320 00:11:11,254 --> 00:11:13,630 I could have a catastrophic failure, 321 00:11:13,715 --> 00:11:15,674 and especially after my last quench. 322 00:11:15,759 --> 00:11:17,509 But, you know, this is a competition, 323 00:11:17,552 --> 00:11:19,344 and I've gotta make some kind of details 324 00:11:19,429 --> 00:11:20,679 'cause it's just too boring. 325 00:11:20,722 --> 00:11:22,472 Let's do it. 326 00:11:22,516 --> 00:11:24,391 - Beau's in for his third quench. 327 00:11:24,476 --> 00:11:25,934 - I pull it out. 328 00:11:26,019 --> 00:11:28,186 I get the file. It skates right across it. 329 00:11:28,271 --> 00:11:29,771 We're good. 330 00:11:29,856 --> 00:11:31,815 I'm ready to move on, back to the grinder. 331 00:11:31,900 --> 00:11:34,359 [grinder buzzing] 332 00:11:34,403 --> 00:11:35,652 ♪ ♪ 333 00:11:35,737 --> 00:11:37,153 - I'm looking at my piece inside the forge, 334 00:11:37,239 --> 00:11:38,488 and I'm getting ready to quench it. 335 00:11:38,573 --> 00:11:40,031 - That looks like a melted stick of butter. 336 00:11:40,075 --> 00:11:41,408 Look at that thing. 337 00:11:41,493 --> 00:11:43,076 - Put her in the quench. I pull my blade out. 338 00:11:43,161 --> 00:11:44,577 I see good color. 339 00:11:44,663 --> 00:11:46,871 The blade does have a little bit of twist to it, 340 00:11:46,915 --> 00:11:49,541 but I know that I can get that out by hand. 341 00:11:49,584 --> 00:11:50,750 ♪ ♪ 342 00:11:50,794 --> 00:11:53,920 - gentlemen, you have 20 minutes remaining. 343 00:11:54,005 --> 00:11:56,339 - My blade looks good. 344 00:11:56,383 --> 00:11:57,507 I'm about to put it in the quench. 345 00:11:57,551 --> 00:11:58,508 - Ah, that's hot! - Oh, boy. 346 00:11:58,593 --> 00:11:59,926 ♪ ♪ 347 00:12:00,011 --> 00:12:02,929 - I file-test, and it skates. 348 00:12:03,014 --> 00:12:04,556 It feels good. 349 00:12:04,641 --> 00:12:06,516 Yay! 350 00:12:06,560 --> 00:12:08,059 But I gotta make sure 351 00:12:08,103 --> 00:12:09,894 that I've met the parameters on length. 352 00:12:09,980 --> 00:12:12,355 I look down, and... 353 00:12:12,441 --> 00:12:14,607 I'm a few inches shy. 354 00:12:14,693 --> 00:12:16,609 And my heart just drops. 355 00:12:16,695 --> 00:12:19,738 [dramatic music] 356 00:12:19,781 --> 00:12:21,364 why did I do that? 357 00:12:21,408 --> 00:12:22,866 I don't know what to do. 358 00:12:22,909 --> 00:12:24,868 - Don't quit. Keep going. 359 00:12:24,911 --> 00:12:27,036 - I missed parameter. 360 00:12:27,122 --> 00:12:28,872 - Heat it up and give it one more... 361 00:12:28,957 --> 00:12:30,790 [imitates squirt] 362 00:12:30,876 --> 00:12:32,625 - beau saved me again. 363 00:12:32,711 --> 00:12:35,420 And I'm like, "well, go big or go home." 364 00:12:35,464 --> 00:12:36,921 - attaboy. - All right! 365 00:12:36,965 --> 00:12:38,131 Good job! 366 00:12:38,216 --> 00:12:40,216 - I don't want my kids seeing me quit. 367 00:12:40,260 --> 00:12:42,385 So I have to see this through. 368 00:12:42,429 --> 00:12:44,929 Whoo! 369 00:12:44,973 --> 00:12:46,723 ♪ ♪ 370 00:12:46,808 --> 00:12:48,057 - I'm checking my blade, 371 00:12:48,143 --> 00:12:50,769 and I have a slight warp near the tang. 372 00:12:50,812 --> 00:12:52,270 ♪ ♪ 373 00:12:52,355 --> 00:12:54,439 - could that have anything to do with his quench? 374 00:12:54,524 --> 00:12:56,775 - It could be, yeah. 375 00:12:56,818 --> 00:12:58,526 - I put my blade in the vice, 376 00:12:58,612 --> 00:13:01,237 just to try to straighten it out, just a little bit. 377 00:13:01,281 --> 00:13:04,115 It's working...Almost. 378 00:13:04,159 --> 00:13:07,786 I still have ever-so-slightly of a bend to it. 379 00:13:07,871 --> 00:13:10,288 I decide that I'm going to blue back the spine, 380 00:13:10,332 --> 00:13:11,956 to help soften the blade. 381 00:13:12,000 --> 00:13:14,918 - If you notice that warp on aric's blade, 382 00:13:14,961 --> 00:13:16,419 it's not in the spine. 383 00:13:16,463 --> 00:13:17,837 It's the entire blade. 384 00:13:17,923 --> 00:13:19,631 - So would the best course of action right now just be 385 00:13:19,716 --> 00:13:21,591 throw it back in the forge and work it out? 386 00:13:21,676 --> 00:13:23,259 ♪ ♪ 387 00:13:23,345 --> 00:13:26,179 - if I go too much on the vice, 388 00:13:26,264 --> 00:13:27,764 the blade could snap. 389 00:13:27,849 --> 00:13:30,850 So I decide that I'm not gonna press my luck any further 390 00:13:30,936 --> 00:13:33,269 and I'm gonna grind the rest of it out. 391 00:13:33,355 --> 00:13:35,772 ♪ ♪ 392 00:13:35,857 --> 00:13:37,315 - five, 393 00:13:37,359 --> 00:13:38,983 four, three, 394 00:13:39,027 --> 00:13:40,652 two, one. 395 00:13:40,695 --> 00:13:42,654 Turn off your machines. Put down your tools. 396 00:13:42,739 --> 00:13:45,657 Round one is officially over. 397 00:13:45,742 --> 00:13:48,660 - I'm emotionally exhausted. 398 00:13:48,703 --> 00:13:51,454 I'm just praying that I met all the parameters, 399 00:13:51,540 --> 00:13:54,290 because it keeps coming back to bite me in the butt. 400 00:13:54,376 --> 00:13:55,667 - All right, gentlemen. 401 00:13:55,710 --> 00:13:57,502 It is time for the judges to give their critique. 402 00:13:57,587 --> 00:13:59,671 See who's gonna be moving to round two of the competition 403 00:13:59,756 --> 00:14:01,548 and who's gonna be heading home. 404 00:14:01,633 --> 00:14:02,841 Beau, you ready? - Ready. 405 00:14:02,884 --> 00:14:04,509 - All right. Let's see what you got. 406 00:14:04,553 --> 00:14:08,346 ♪ ♪ 407 00:14:08,431 --> 00:14:10,682 - all right, buddy. Your steel looks good. 408 00:14:10,725 --> 00:14:12,517 I mean, you've got some wiggle to it. 409 00:14:12,561 --> 00:14:14,519 I mean, you can see the blade edge... 410 00:14:14,563 --> 00:14:15,854 - Mm-hmm. 411 00:14:15,939 --> 00:14:17,689 - Is like waves on the lake. 412 00:14:17,732 --> 00:14:19,357 But there's more than enough mass on here. 413 00:14:19,442 --> 00:14:21,526 You can clean that up on a grinder. 414 00:14:21,611 --> 00:14:23,695 [laughing] your handle is... 415 00:14:23,780 --> 00:14:25,864 A bit on the large side. 416 00:14:25,907 --> 00:14:27,532 So hopefully you'll take those into consideration 417 00:14:27,617 --> 00:14:29,993 and refine this if you move to the next round. 418 00:14:30,078 --> 00:14:31,202 - All right, kevin. You ready? 419 00:14:31,246 --> 00:14:32,203 - Yes, I am. - All right. 420 00:14:32,289 --> 00:14:33,538 Let's see what you came up with. 421 00:14:33,582 --> 00:14:35,373 ♪ ♪ 422 00:14:35,458 --> 00:14:37,542 - kevin, first off, your steel looks good. 423 00:14:37,586 --> 00:14:38,960 ♪ ♪ 424 00:14:39,045 --> 00:14:41,588 I like the integral bolster that you added to this. 425 00:14:41,673 --> 00:14:42,881 Big thing is 426 00:14:42,924 --> 00:14:45,884 this tang is totally cantered off to one side. 427 00:14:45,927 --> 00:14:47,051 It needs some work, 428 00:14:47,137 --> 00:14:48,344 but I like where you're going with it. 429 00:14:48,430 --> 00:14:49,512 Good job. - Thank you. 430 00:14:49,556 --> 00:14:50,680 - All right, aric. You're up next. 431 00:14:50,765 --> 00:14:51,848 You ready? - I'm ready. 432 00:14:51,892 --> 00:14:53,016 All right. Let's see what you got. 433 00:14:53,101 --> 00:14:56,185 ♪ ♪ 434 00:14:56,229 --> 00:14:58,062 - right off, like the profile. 435 00:14:58,148 --> 00:14:59,355 You drew this thing out. 436 00:14:59,399 --> 00:15:00,607 That's one lean blade. 437 00:15:00,692 --> 00:15:02,066 So hopefully you got your thermal cycling 438 00:15:02,152 --> 00:15:03,401 all dialed in. 439 00:15:03,445 --> 00:15:05,361 There is a warp in your blade. 440 00:15:05,447 --> 00:15:07,906 You got a spinner. - [chuckles] 441 00:15:07,991 --> 00:15:09,240 - love to see that taken out 442 00:15:09,326 --> 00:15:11,075 because I think you've done a really good job. 443 00:15:11,161 --> 00:15:12,076 That's a good design. 444 00:15:12,162 --> 00:15:13,411 - Thank you. 445 00:15:13,455 --> 00:15:15,538 - All right, starlin. Please present your work. 446 00:15:15,624 --> 00:15:18,791 ♪ ♪ 447 00:15:18,877 --> 00:15:20,126 - well, starlin, 448 00:15:20,211 --> 00:15:21,753 we noticed that you were struggling 449 00:15:21,796 --> 00:15:24,255 to really get the width and the length of your blade. 450 00:15:24,299 --> 00:15:25,632 So now it's time to find out 451 00:15:25,717 --> 00:15:27,717 if you actually were able to get that length. 452 00:15:27,802 --> 00:15:31,262 [dramatic music] 453 00:15:31,348 --> 00:15:34,599 our parameters were 12 to 14 inches... 454 00:15:34,643 --> 00:15:37,268 And you are at exactly 11. 455 00:15:37,312 --> 00:15:38,770 ♪ ♪ 456 00:15:38,813 --> 00:15:40,980 I really appreciate that you kept on going, 457 00:15:41,066 --> 00:15:44,108 but unfortunately, you didn't make our parameters. 458 00:15:44,152 --> 00:15:45,818 - Starlin, I wanna thank you for your hard work 459 00:15:45,904 --> 00:15:48,154 and no-quit mentality, but unfortunately, 460 00:15:48,239 --> 00:15:49,656 your blade did not meet parameters. 461 00:15:49,699 --> 00:15:52,241 So I'm gonna have to ask you to please leave the forge. 462 00:15:52,327 --> 00:15:53,618 - Thank you, guys, for this opportunity. 463 00:15:53,703 --> 00:15:54,953 - Well done, man. - Thank you, starlin. 464 00:15:55,038 --> 00:15:56,162 - Good job, man. - Thank you. 465 00:15:56,247 --> 00:15:58,623 - I gotta be honest; it sucks. 466 00:15:58,708 --> 00:16:01,584 I just couldn't draw it out enough 467 00:16:01,670 --> 00:16:03,628 to meet the parameters in time. 468 00:16:03,672 --> 00:16:04,837 If there's one thing 469 00:16:04,923 --> 00:16:06,464 that I hope my daughters take away from this, 470 00:16:06,549 --> 00:16:09,133 it's that you don't quit and you keep moving forward. 471 00:16:09,177 --> 00:16:10,760 ♪ ♪ 472 00:16:10,804 --> 00:16:11,928 - gentlemen, congratulations. 473 00:16:12,013 --> 00:16:13,596 The three of you are moving forward 474 00:16:13,640 --> 00:16:15,473 into round two of our competition. 475 00:16:15,517 --> 00:16:17,141 Now, in round two of the competition, 476 00:16:17,185 --> 00:16:19,435 you guys are gonna fix any issues the judges brought up 477 00:16:19,521 --> 00:16:21,145 while also adding handles to your blades, 478 00:16:21,231 --> 00:16:23,272 making them fully functioning weapons. 479 00:16:23,316 --> 00:16:24,649 If you guys look over to your right, 480 00:16:24,693 --> 00:16:26,651 you see we've got a pile of burnt-out wood 481 00:16:26,695 --> 00:16:28,152 we found in the suv. 482 00:16:28,196 --> 00:16:31,364 That is all you have for your handle material. 483 00:16:31,449 --> 00:16:33,700 Anybody used burnt wood before? 484 00:16:33,785 --> 00:16:35,076 No? Not yet? 485 00:16:35,161 --> 00:16:36,828 Well, there's a first time for everything. 486 00:16:36,871 --> 00:16:38,204 ♪ ♪ 487 00:16:38,289 --> 00:16:40,331 now, after you've put your handles on your blades, 488 00:16:40,375 --> 00:16:42,500 we're gonna be testing them for strength and durability 489 00:16:42,544 --> 00:16:44,168 in a tailgate chop 490 00:16:44,254 --> 00:16:46,921 and for sharpness in a fuel-hose slice. 491 00:16:47,007 --> 00:16:49,674 All right, guys. As always, watch the clock. 492 00:16:49,718 --> 00:16:51,175 You will only have two hours 493 00:16:51,219 --> 00:16:52,468 in round two of the competition. 494 00:16:52,554 --> 00:16:54,178 And that time starts now. 495 00:16:54,264 --> 00:16:58,016 [heavy rock music] 496 00:16:58,059 --> 00:16:59,767 - all right. 497 00:16:59,853 --> 00:17:02,520 - This is about 2-inch-thick seasoned oak. 498 00:17:02,564 --> 00:17:04,480 Good, solid wood to make handles out of. 499 00:17:04,524 --> 00:17:07,567 - First thing I'm gonna do is I'm gonna grab a sharpie, 500 00:17:07,652 --> 00:17:11,029 kinda draw myself a new profile that I think's appropriate. 501 00:17:11,072 --> 00:17:13,865 And I'm gonna cut off any excess beyond that. 502 00:17:13,908 --> 00:17:15,324 - Beau just shortened his blade up. 503 00:17:15,410 --> 00:17:17,535 - [sighs] all right. What do we got here? 504 00:17:17,620 --> 00:17:19,704 So all this wood looks the same to me. 505 00:17:19,789 --> 00:17:22,040 That's hard stuff. 506 00:17:22,125 --> 00:17:24,709 It sounds solid, so I'm just gonna run with it. 507 00:17:24,794 --> 00:17:26,669 Seems good. 508 00:17:26,755 --> 00:17:29,172 ♪ ♪ 509 00:17:29,257 --> 00:17:31,049 - I don't think there's anybody else 510 00:17:31,134 --> 00:17:33,926 that burns their wood before they put it on the handle. 511 00:17:34,012 --> 00:17:36,679 That's only something you'll find on "forged in fire." 512 00:17:36,765 --> 00:17:40,516 for me, the big challenge is getting the warp out. 513 00:17:40,602 --> 00:17:41,851 ♪ ♪ 514 00:17:41,936 --> 00:17:43,895 what I'm gonna do is heat up the spine 515 00:17:43,938 --> 00:17:46,564 and I'm gonna just bend it slowly back to straight. 516 00:17:46,608 --> 00:17:48,733 ♪ ♪ 517 00:17:48,777 --> 00:17:51,861 - he should be able to warp that thing almost 30 degrees 518 00:17:51,905 --> 00:17:53,905 and have it come back and be fine. 519 00:17:53,990 --> 00:17:55,740 - That's more better, less worse. 520 00:17:55,825 --> 00:17:57,575 I got most of the warp out. 521 00:17:57,619 --> 00:17:58,910 - Did you guys see aric's blade? 522 00:17:58,995 --> 00:18:00,411 - Yeah. It's no longer spinning. 523 00:18:00,455 --> 00:18:02,747 - Now I'm ready to start working on my handle. 524 00:18:02,791 --> 00:18:06,042 ♪ ♪ 525 00:18:06,127 --> 00:18:09,087 - the problem with using burnt wood is... 526 00:18:09,172 --> 00:18:10,755 You don't know what it is. 527 00:18:10,799 --> 00:18:13,299 - Beau and kevin did a thing where they do a smash test. 528 00:18:13,384 --> 00:18:15,426 Hit it hard on the ground, see if it's solid inside, 529 00:18:15,512 --> 00:18:16,928 and they go, "it'll pass." 530 00:18:16,971 --> 00:18:19,013 - I only see a little bit of charring come off. 531 00:18:19,099 --> 00:18:20,556 I know the rest of the wood is good and solid. 532 00:18:20,600 --> 00:18:22,433 So that's the piece I'm gonna use. 533 00:18:22,477 --> 00:18:24,102 - These are pretty much thick pieces. 534 00:18:24,145 --> 00:18:26,938 If you're worried about the char, just go for the core. 535 00:18:26,981 --> 00:18:28,940 ♪ ♪ 536 00:18:28,983 --> 00:18:31,442 - the actual edge is not a straight line 537 00:18:31,528 --> 00:18:33,611 or a continuous curve. 538 00:18:33,655 --> 00:18:34,946 It doesn't look very nice. 539 00:18:35,031 --> 00:18:36,364 So I'm gonna have to take care of that. 540 00:18:36,449 --> 00:18:38,241 - J., you were talking about beau's blade. 541 00:18:38,326 --> 00:18:39,575 What can he be doing to fix that? 542 00:18:39,661 --> 00:18:40,993 - I would've liked to have seen him just 543 00:18:41,079 --> 00:18:42,411 put that on the flat--flatten. 544 00:18:42,455 --> 00:18:44,455 That way, you got a nice, even line. 545 00:18:44,499 --> 00:18:47,458 'cause it looked like something had gnawed on the edge 546 00:18:47,502 --> 00:18:49,585 for a couple hundred years, or something like that. 547 00:18:49,671 --> 00:18:50,837 - All right, bladesmiths. 548 00:18:50,922 --> 00:18:52,755 There's one hour remaining on the clock. 549 00:18:52,841 --> 00:18:55,800 - ♪ I gotta hurry, I gotta hurry ♪ 550 00:18:55,885 --> 00:18:58,302 ♪ I gotta hurry, hurry, hurry ♪ 551 00:18:58,346 --> 00:19:01,264 - I get my holes drilled through my handle, 552 00:19:01,349 --> 00:19:04,517 but I'm having a hard time getting the pins to go in. 553 00:19:04,602 --> 00:19:06,144 [groans] 554 00:19:06,187 --> 00:19:07,353 [bleep] 555 00:19:07,438 --> 00:19:09,105 I don't wanna just keep forcing it together. 556 00:19:09,149 --> 00:19:10,648 - See how long those pins are? 557 00:19:10,692 --> 00:19:12,775 Any kind of variation in those holes 558 00:19:12,861 --> 00:19:14,944 puts those pins out of alignment. 559 00:19:15,029 --> 00:19:18,281 So it's easier to start with those pins kind of short, 560 00:19:18,366 --> 00:19:20,449 get things lined up, then push them through. 561 00:19:22,996 --> 00:19:24,245 ♪ ♪ 562 00:19:24,289 --> 00:19:26,247 - I'm trying to get the pins to go through. 563 00:19:26,332 --> 00:19:28,207 I'm trying to get everything lined up. 564 00:19:28,293 --> 00:19:30,459 It's close, but it's just quite not there. 565 00:19:30,503 --> 00:19:32,628 Hmm... 566 00:19:32,714 --> 00:19:34,172 I don't wanna force it. 567 00:19:34,215 --> 00:19:36,299 So I'm constantly going back to the drill press, 568 00:19:36,384 --> 00:19:37,758 check it again. 569 00:19:37,844 --> 00:19:39,343 That's better. 570 00:19:39,387 --> 00:19:40,761 I don't know what I did differently, 571 00:19:40,847 --> 00:19:43,347 but I get it to go together, and we're in business. 572 00:19:43,391 --> 00:19:47,351 ♪ ♪ 573 00:19:47,437 --> 00:19:51,647 - I need by tang fixed before I can even put my handle on. 574 00:19:51,733 --> 00:19:53,733 I've got to keep the blade cool 575 00:19:53,818 --> 00:19:55,484 so it doesn't lose my heat treat. 576 00:19:55,570 --> 00:19:57,153 So I wrap it in some wet towels, 577 00:19:57,238 --> 00:19:59,363 heat up the tang from the bolster back 578 00:19:59,407 --> 00:20:00,865 just so I can straighten it. 579 00:20:00,950 --> 00:20:02,074 - Kevin's back there, 580 00:20:02,160 --> 00:20:03,576 putting some serious torque on that tang, 581 00:20:03,661 --> 00:20:04,702 trying to straighten it out. 582 00:20:04,746 --> 00:20:06,204 - I got my tang straight. 583 00:20:06,247 --> 00:20:07,622 There's a little bit of grinding I can do 584 00:20:07,707 --> 00:20:10,458 to get some of the little imperfections out. 585 00:20:10,543 --> 00:20:11,542 I'm happy with it. 586 00:20:11,586 --> 00:20:12,501 ♪ ♪ 587 00:20:12,545 --> 00:20:13,586 great. 588 00:20:13,671 --> 00:20:14,879 - The way this handle fits 589 00:20:14,923 --> 00:20:16,672 in the judges hands is so important. 590 00:20:16,758 --> 00:20:19,717 They got a lot of power coming down on these chops. 591 00:20:19,761 --> 00:20:22,053 So what I'm doing now is putting these deep contours 592 00:20:22,138 --> 00:20:24,222 in the handle for the judges' hands. 593 00:20:24,265 --> 00:20:25,640 - Is there a point 594 00:20:25,725 --> 00:20:28,184 where contouring and adding shapes into your handle 595 00:20:28,269 --> 00:20:29,852 just gets to be too much? 596 00:20:29,896 --> 00:20:32,230 - If you don't contour it properly, 597 00:20:32,273 --> 00:20:34,565 then you're gonna have a knife that's more comfortable 598 00:20:34,609 --> 00:20:37,485 holding a blade this way as opposed to this way. 599 00:20:37,570 --> 00:20:39,904 - That's not effective. - That's not as effective. 600 00:20:39,948 --> 00:20:42,990 - I think I put a nice handle on this piece. 601 00:20:43,076 --> 00:20:44,659 I hope I got it sharp enough for the test, 602 00:20:44,744 --> 00:20:45,826 but I feel good. 603 00:20:45,912 --> 00:20:47,745 Whoo! 604 00:20:47,789 --> 00:20:50,039 ♪ ♪ 605 00:20:50,124 --> 00:20:51,207 - I take the clamps off 606 00:20:51,251 --> 00:20:53,125 and I cut off the excess of my pins. 607 00:20:53,211 --> 00:20:55,544 And I peen the pins 608 00:20:55,630 --> 00:20:58,589 so that they have a more solid, mechanical hold. 609 00:20:58,633 --> 00:21:01,092 - Okay, this is what makes me crazy: 610 00:21:01,135 --> 00:21:04,053 Using a hammer that size to try to mushroom out a pin, 611 00:21:04,138 --> 00:21:07,098 is just a great way to crack handle material. 612 00:21:07,141 --> 00:21:09,684 ♪ ♪ 613 00:21:09,769 --> 00:21:13,437 - my next step is to go over to the grinder 614 00:21:13,523 --> 00:21:16,607 until I get a shape that feels comfortable. 615 00:21:16,651 --> 00:21:17,942 ♪ ♪ 616 00:21:17,986 --> 00:21:20,361 my biggest concern right now is, honestly, 617 00:21:20,446 --> 00:21:21,779 my blade snapping when they smash it 618 00:21:21,823 --> 00:21:23,447 into a truck bed. 619 00:21:23,491 --> 00:21:25,741 So I got a little bit of time left on the clock. 620 00:21:25,785 --> 00:21:28,286 I'm gonna make this blade awesome. 621 00:21:28,329 --> 00:21:30,454 I find some clear nail polish. 622 00:21:30,498 --> 00:21:33,624 I paint on the blade, "forged in fire, " 623 00:21:33,710 --> 00:21:36,919 and I go into the acid for a few minutes. 624 00:21:36,963 --> 00:21:38,796 I'm borrowing your acid. 625 00:21:38,840 --> 00:21:39,797 - Go ahead. 626 00:21:39,841 --> 00:21:42,758 ♪ ♪ 627 00:21:42,802 --> 00:21:45,636 - it is one awesome-looking knife. 628 00:21:45,680 --> 00:21:47,847 ♪ ♪ 629 00:21:47,932 --> 00:21:49,432 - I pride myself on putting a good handle 630 00:21:49,475 --> 00:21:51,100 on the piece that I make 631 00:21:51,144 --> 00:21:54,979 because a handle on a blade is an interface. 632 00:21:55,023 --> 00:21:56,981 So it's like a keyboard on a computer. 633 00:21:57,066 --> 00:21:58,399 I'm gonna flare out the ends 634 00:21:58,484 --> 00:22:00,693 so your hand stays in a good gripping position. 635 00:22:00,778 --> 00:22:03,487 - Five...Four...Three... 636 00:22:03,573 --> 00:22:05,656 Two...One. 637 00:22:05,700 --> 00:22:07,742 Put down your tools. Turn off your machines. 638 00:22:07,827 --> 00:22:10,536 Round two is over. 639 00:22:10,621 --> 00:22:14,123 - Obviously, my big fear right now is a blade break. 640 00:22:14,208 --> 00:22:16,459 I don't think it's terribly likely that it's gonna happen, 641 00:22:16,544 --> 00:22:18,169 but it's all up to the tests now. 642 00:22:18,212 --> 00:22:20,212 - You guys ready for a tailgate party? 643 00:22:20,298 --> 00:22:21,422 - Not my kind of tailgate party. 644 00:22:21,507 --> 00:22:24,967 [laughter] - welcome to the strength test. 645 00:22:25,053 --> 00:22:26,302 Or tailgate chop. 646 00:22:26,387 --> 00:22:27,845 [dramatic music] 647 00:22:27,930 --> 00:22:30,181 now I'm gonna take each of your knives 648 00:22:30,224 --> 00:22:32,808 and repeatedly and mercilessly beat them 649 00:22:32,894 --> 00:22:34,602 into this suv liftgate. 650 00:22:34,687 --> 00:22:36,520 What your blades do to this liftgate, 651 00:22:36,564 --> 00:22:37,855 I'm not too concerned about. 652 00:22:37,899 --> 00:22:39,648 I wanna see what the gate does to your blades. 653 00:22:39,734 --> 00:22:41,150 Beau, you're up first. How you feeling? 654 00:22:41,194 --> 00:22:43,194 - Get some, j. - All right. 655 00:22:43,237 --> 00:22:44,862 ♪ ♪ 656 00:22:44,906 --> 00:22:48,491 - I'm nervous about j., how hard he hits these knives. 657 00:22:48,576 --> 00:22:50,034 I did have to quench three times. 658 00:22:50,078 --> 00:22:52,203 I just hope I got my heat treatment right. 659 00:22:52,246 --> 00:22:55,039 ♪ ♪ 660 00:22:55,083 --> 00:22:56,749 [heavy rock music] 661 00:22:56,834 --> 00:22:58,876 - [grunting] 662 00:22:58,920 --> 00:23:01,128 ♪ ♪ 663 00:23:01,214 --> 00:23:02,129 I'm not done. 664 00:23:02,215 --> 00:23:03,672 [all chuckle] 665 00:23:03,716 --> 00:23:05,216 [grunts] 666 00:23:05,259 --> 00:23:06,217 ♪ ♪ 667 00:23:07,053 --> 00:23:08,052 ♪ ♪ 668 00:23:08,137 --> 00:23:09,720 it survived, beau. - It did. 669 00:23:09,806 --> 00:23:11,097 - Good job. 670 00:23:11,182 --> 00:23:13,391 You do have some spots, a little bit of rolling. 671 00:23:13,476 --> 00:23:15,684 There's a couple spots, like right down here, 672 00:23:15,728 --> 00:23:17,144 where there's really not an edge. 673 00:23:17,230 --> 00:23:18,187 - Hmm. 674 00:23:18,231 --> 00:23:19,855 - The handle is still secure. 675 00:23:19,899 --> 00:23:22,316 It's just, right in here, this spot, 676 00:23:22,402 --> 00:23:24,068 even though you've got it contoured, 677 00:23:24,112 --> 00:23:25,194 this kinda digs in. 678 00:23:25,238 --> 00:23:26,404 But didn't fly apart. 679 00:23:26,447 --> 00:23:27,571 Good job. - I'll take it. 680 00:23:27,615 --> 00:23:29,949 Thank you, j. - Kevin, how you feeling? 681 00:23:30,034 --> 00:23:31,283 - Nervous. - I'm not nervous. 682 00:23:31,369 --> 00:23:32,410 Let's do it. 683 00:23:32,453 --> 00:23:34,036 ♪ ♪ 684 00:23:34,080 --> 00:23:35,704 - I'm very nervous. 685 00:23:35,790 --> 00:23:39,250 Did I heat-treat correct? Is my edge gonna last? 686 00:23:39,293 --> 00:23:41,919 So just gotta hope for the best. 687 00:23:41,963 --> 00:23:43,087 [heavy rock music] 688 00:23:43,172 --> 00:23:45,923 - [grunting] 689 00:23:45,967 --> 00:23:51,345 ♪ ♪ 690 00:23:51,431 --> 00:23:53,097 - good job. - Phew. 691 00:23:53,141 --> 00:23:54,515 [tense music] 692 00:23:54,600 --> 00:23:56,225 - good job, kevin. - Thank you. 693 00:23:56,269 --> 00:23:58,060 - You got, I mean, the slightest-- 694 00:23:58,146 --> 00:24:00,438 I mean, you know, it's barely catch a nail, 695 00:24:00,523 --> 00:24:02,189 little bit of rolling. 696 00:24:02,275 --> 00:24:03,732 It's still straight as it was. 697 00:24:03,818 --> 00:24:05,943 Only problem I have is, 698 00:24:06,028 --> 00:24:07,945 when you're doing an integral, 699 00:24:07,989 --> 00:24:09,655 this tends to become part of your handle 700 00:24:09,740 --> 00:24:11,073 as opposed to a guard. 701 00:24:11,117 --> 00:24:13,617 So there's a lot of handle left over. 702 00:24:13,661 --> 00:24:15,411 But nothing moved. 703 00:24:15,496 --> 00:24:17,288 You survived the tailgate chop. Good job. 704 00:24:17,373 --> 00:24:19,790 - Thank you. - And then there was aric. 705 00:24:19,834 --> 00:24:21,417 - Then there was aric. - Ready to go? 706 00:24:21,502 --> 00:24:23,461 - Give it hell. - That, I can do. 707 00:24:23,546 --> 00:24:26,088 - It's very nerve-racking, 708 00:24:26,174 --> 00:24:27,882 seeing the type of steel 709 00:24:27,967 --> 00:24:29,633 that it's gonna be bashed into. 710 00:24:29,677 --> 00:24:31,093 That's a hard piece of metal. 711 00:24:31,179 --> 00:24:33,762 That's gonna do a lot of damage. 712 00:24:33,806 --> 00:24:36,307 [heavy metal music] 713 00:24:36,350 --> 00:24:38,309 - [grunting] 714 00:24:38,352 --> 00:24:44,148 ♪ ♪ 715 00:24:45,067 --> 00:24:46,484 - [exhales] 716 00:24:46,527 --> 00:24:47,776 ♪ ♪ 717 00:24:47,862 --> 00:24:49,153 - all right, aric. You survived. 718 00:24:49,197 --> 00:24:50,112 Good job. 719 00:24:50,198 --> 00:24:51,489 We do have a few issues, though. 720 00:24:51,574 --> 00:24:53,324 You can see you got chipping and rolling 721 00:24:53,367 --> 00:24:54,617 from there to there. 722 00:24:54,702 --> 00:24:57,411 That being said, it held up extremely well. 723 00:24:57,497 --> 00:24:59,455 The handle, I like the contouring you did. 724 00:24:59,499 --> 00:25:01,665 But the problem is, it's still pretty round. 725 00:25:01,709 --> 00:25:03,918 I could pretty easily spin this in my hand. 726 00:25:04,003 --> 00:25:05,753 But that being said, it's still in one piece. 727 00:25:05,838 --> 00:25:07,838 Good job. - Thank you. 728 00:25:07,882 --> 00:25:10,466 ♪ ♪ 729 00:25:10,551 --> 00:25:12,009 - all right, bladesmiths. 730 00:25:12,094 --> 00:25:15,179 Congratulations for surviving j.'s tailgate party. 731 00:25:15,223 --> 00:25:17,806 But now it's time to find out what kind of edge 732 00:25:17,850 --> 00:25:19,517 you have left on your blades. 733 00:25:19,560 --> 00:25:21,685 This is the sharpness test. 734 00:25:21,729 --> 00:25:23,145 The fuel-hose slice. 735 00:25:23,231 --> 00:25:24,396 [dramatic music] 736 00:25:24,440 --> 00:25:26,565 now, to find out how sharp your weapons are, 737 00:25:26,651 --> 00:25:27,691 I will take your weapons 738 00:25:27,735 --> 00:25:29,735 and try to cut through these fuel hose. 739 00:25:29,820 --> 00:25:32,321 Now, unlike the strength test, 740 00:25:32,406 --> 00:25:33,531 this is all about 741 00:25:33,574 --> 00:25:35,115 what your edge will do to these hose. 742 00:25:35,201 --> 00:25:36,534 Beau, you're up first. You ready for this? 743 00:25:36,619 --> 00:25:37,701 - I'm ready. 744 00:25:40,289 --> 00:25:42,456 ♪ ♪ 745 00:25:42,542 --> 00:25:43,624 - I definitely got some jitters. I definitely got some jitters. I have some edge r 746 00:25:43,709 --> 00:25:45,584 I have some edge rolling. 747 00:25:45,670 --> 00:25:49,380 That's gonna make slicing those fuel lines very tough. 748 00:25:49,423 --> 00:25:55,427 ♪ ♪ 749 00:25:55,513 --> 00:25:56,887 [groans softly] 750 00:25:56,931 --> 00:25:58,472 ♪ ♪ 751 00:25:58,558 --> 00:25:59,598 - all right, beau. 752 00:25:59,684 --> 00:26:01,767 First up, your handle construction. 753 00:26:01,852 --> 00:26:03,394 It fits my hand nicely. 754 00:26:03,479 --> 00:26:04,770 Now your edge. 755 00:26:04,855 --> 00:26:06,689 It's not very sharp all the way through. 756 00:26:06,774 --> 00:26:08,524 The fuel hose--it cut it, 757 00:26:08,609 --> 00:26:10,734 but it didn't cut all the way through. 758 00:26:10,778 --> 00:26:13,028 But overall, we know it will cut. 759 00:26:13,114 --> 00:26:14,572 - [chuckles] thank you. - All right, kevin. 760 00:26:14,657 --> 00:26:15,739 Your turn. So are you ready? 761 00:26:15,783 --> 00:26:17,032 - Oh, yes. - Let's do this. 762 00:26:17,118 --> 00:26:24,081 ♪ ♪ 763 00:26:24,166 --> 00:26:26,292 - ooh. - All right, kevin. 764 00:26:26,377 --> 00:26:27,585 Let's talk about your weapon, here. 765 00:26:27,628 --> 00:26:30,087 First up, I like the handle construction. 766 00:26:30,131 --> 00:26:31,922 I really appreciate the integral part 767 00:26:32,008 --> 00:26:33,382 that you put into your handle here. 768 00:26:33,426 --> 00:26:34,508 It's got a nice feel to it. 769 00:26:34,594 --> 00:26:35,926 I love that you curved it, 770 00:26:35,970 --> 00:26:37,678 because with a heavier front blade like this, 771 00:26:37,763 --> 00:26:40,097 it's nice to be able to have that control. 772 00:26:40,141 --> 00:26:41,640 Now your edge here. 773 00:26:41,684 --> 00:26:44,184 Looks like the strength test really dulled your blade also. 774 00:26:44,270 --> 00:26:47,271 It cut the first hose, but not all the way through. 775 00:26:47,356 --> 00:26:49,773 But overall, sir, we know...It cuts. 776 00:26:49,817 --> 00:26:51,108 - All right. Thank you. 777 00:26:51,152 --> 00:26:52,109 - All right, aric. Your turn. 778 00:26:52,194 --> 00:26:53,485 So, you ready? - I'm ready. 779 00:26:53,571 --> 00:26:54,737 - Let's do this. 780 00:26:54,822 --> 00:26:59,783 ♪ ♪ 781 00:27:00,953 --> 00:27:01,994 [tense music] 782 00:27:02,079 --> 00:27:03,287 all right, aric. 783 00:27:03,372 --> 00:27:04,913 Now, your handle construction is very smooth. 784 00:27:04,999 --> 00:27:06,206 I like the flair that you have. 785 00:27:06,292 --> 00:27:08,542 I can see where it can rotate a little bit. 786 00:27:08,628 --> 00:27:10,127 Now your edge. 787 00:27:10,212 --> 00:27:12,296 During the strength test, it took some dulling. 788 00:27:12,381 --> 00:27:15,007 But because it is so thin, 789 00:27:15,092 --> 00:27:18,010 it actually works for this particular test. 790 00:27:18,095 --> 00:27:20,471 Overall, sir, your weapon...It will cut. 791 00:27:20,556 --> 00:27:21,472 - Thank you. 792 00:27:21,515 --> 00:27:23,474 ♪ ♪ 793 00:27:23,559 --> 00:27:24,808 - we gave you guys a hard challenge, 794 00:27:24,852 --> 00:27:27,269 and you all performed really well on our test. 795 00:27:27,355 --> 00:27:28,479 But the judges have deliberated, 796 00:27:28,564 --> 00:27:29,980 and only two of you can go forward 797 00:27:30,066 --> 00:27:31,690 into round three of the competition. 798 00:27:31,776 --> 00:27:33,859 And the bladesmith leaving the forge is... 799 00:27:33,944 --> 00:27:37,237 [dramatic music] 800 00:27:37,323 --> 00:27:38,364 beau. 801 00:27:38,449 --> 00:27:39,865 Unfortunately, you're not going forward 802 00:27:39,950 --> 00:27:41,283 into the next round of the competition, 803 00:27:41,327 --> 00:27:42,868 and j. Is gonna tell you why. 804 00:27:42,953 --> 00:27:44,995 Beau, you guys performed pretty equally in the strength test. 805 00:27:45,081 --> 00:27:47,164 And then the front end of that handle being uncomfortable 806 00:27:47,208 --> 00:27:48,332 to hold onto to very long 807 00:27:48,417 --> 00:27:49,750 are the reasons we're letting you go. 808 00:27:49,835 --> 00:27:51,085 - Okay. 809 00:27:51,170 --> 00:27:52,753 - Beau, we wanna thank you for all your hard work 810 00:27:52,838 --> 00:27:54,755 and especially your great sportsmanship in round one. 811 00:27:54,840 --> 00:27:56,298 But unfortunately, I'm gonna have to ask you 812 00:27:56,384 --> 00:27:57,591 to please step off the forge floor. 813 00:27:57,677 --> 00:27:58,759 - Okay. 814 00:27:58,844 --> 00:28:00,135 Ah, I'm disappointed. 815 00:28:00,221 --> 00:28:01,845 Even though it didn't go my way, 816 00:28:01,889 --> 00:28:03,722 I'm really proud of the work that I did here 817 00:28:03,808 --> 00:28:05,599 and I'm gonna keep on making knives. 818 00:28:05,685 --> 00:28:06,850 ♪ ♪ 819 00:28:06,936 --> 00:28:08,352 - well, kevin, aric, congratulations. 820 00:28:08,396 --> 00:28:10,020 You guys are both moving forward into round three 821 00:28:10,106 --> 00:28:10,979 of our competition, 822 00:28:11,065 --> 00:28:12,398 where we will be sending you home 823 00:28:12,483 --> 00:28:14,650 to work on an iconic weapon from history. 824 00:28:14,694 --> 00:28:15,818 And that weapon is... 825 00:28:15,903 --> 00:28:18,278 ♪ ♪ 826 00:28:18,364 --> 00:28:20,280 the serrated tegha sword. 827 00:28:20,366 --> 00:28:21,824 - Lord have mercy. 828 00:28:21,909 --> 00:28:24,034 ♪ ♪ 829 00:28:24,120 --> 00:28:26,245 - originating in india in the 18th century, 830 00:28:26,330 --> 00:28:27,871 this intimidating curved sword 831 00:28:27,957 --> 00:28:30,249 was known to be a great executioner. 832 00:28:30,334 --> 00:28:33,168 Its unique design features a nearly 3-foot-long blade 833 00:28:33,254 --> 00:28:34,712 with a split tip 834 00:28:34,755 --> 00:28:37,256 and serrated edges that could easily behead a man. 835 00:28:37,341 --> 00:28:39,883 Its two-prong tip is a powerful symbol 836 00:28:39,969 --> 00:28:41,635 throughout the islamic world 837 00:28:41,721 --> 00:28:44,346 and is inspired by the legendary sword zulfiqar, 838 00:28:44,432 --> 00:28:45,889 which is believed to be descended 839 00:28:45,933 --> 00:28:47,725 from the prophet muhammad. 840 00:28:47,768 --> 00:28:50,060 You guys have a lot of parameters to follow, 841 00:28:50,104 --> 00:28:51,729 so pay attention. 842 00:28:51,814 --> 00:28:53,105 You guys need to make a blade 843 00:28:53,190 --> 00:28:55,607 that is between 24 and 26 inches. 844 00:28:55,693 --> 00:28:59,528 That curved depth needs to be no less than 3 1/2 inches. 845 00:28:59,613 --> 00:29:01,405 You need to have a split at the tip 846 00:29:01,490 --> 00:29:04,158 that goes down between 10 and 11 inches, 847 00:29:04,243 --> 00:29:07,244 followed by a puncture hole at the end of that split. 848 00:29:07,329 --> 00:29:09,913 The curved edge and the back edge of the split 849 00:29:09,999 --> 00:29:12,416 need to be serrated and sharpened. 850 00:29:12,501 --> 00:29:14,752 Now, you guys need to have a khanda-style hilt 851 00:29:14,795 --> 00:29:16,170 with a tail pommel. 852 00:29:16,255 --> 00:29:19,173 - I have never seen anything like this in my life. 853 00:29:19,258 --> 00:29:21,967 It's got these crazy curves. It's serrated everywhere. 854 00:29:22,052 --> 00:29:24,970 It just combines so many different skill sets, 855 00:29:25,055 --> 00:29:26,263 it's gonna be a challenge to create. 856 00:29:26,348 --> 00:29:28,432 - You have four days at your home forges. 857 00:29:28,517 --> 00:29:30,309 We'll see you then. 858 00:29:30,394 --> 00:29:32,436 - Good luck. - Good luck to you as well. 859 00:29:32,480 --> 00:29:33,604 - [chuckles] 860 00:29:33,647 --> 00:29:36,273 ♪ ♪ 861 00:29:36,358 --> 00:29:38,609 I'm back in my home forge, 862 00:29:38,652 --> 00:29:42,404 and I'm ready to start working on this serrated tegha. 863 00:29:42,490 --> 00:29:44,114 The length and the curvature of the blade 864 00:29:44,200 --> 00:29:46,575 is something I've never had to deal with before. 865 00:29:46,660 --> 00:29:49,787 Start getting my blade forged to shape. 866 00:29:49,872 --> 00:29:51,580 Looks like a hockey stick. 867 00:29:51,665 --> 00:29:54,249 So now I gotta shape the tip. 868 00:29:54,335 --> 00:29:55,793 That's concerning for me 869 00:29:55,836 --> 00:29:57,377 because the only thing I have to cut metal with 870 00:29:57,463 --> 00:29:58,629 is a grinder. 871 00:29:58,672 --> 00:29:59,797 You don't have a lot of control. 872 00:29:59,882 --> 00:30:02,549 Not pretty, but it's a start. 873 00:30:02,635 --> 00:30:04,301 Getting ready to quench the blade. 874 00:30:04,345 --> 00:30:06,845 ♪ ♪ 875 00:30:06,931 --> 00:30:08,263 she's hard. 876 00:30:08,349 --> 00:30:09,807 The heat treat went good. 877 00:30:09,892 --> 00:30:11,517 It's a lot of work to do yet. 878 00:30:11,602 --> 00:30:13,644 But it's a good start. 879 00:30:13,729 --> 00:30:16,396 [heavy rock music] 880 00:30:16,482 --> 00:30:18,816 - it's good to be back here in my own domain. 881 00:30:18,901 --> 00:30:21,693 I'm gonna be building a serrated tegha sword. 882 00:30:21,779 --> 00:30:24,488 I've never done anything even remotely close to it. 883 00:30:24,532 --> 00:30:26,365 So it's gonna be an exciting build. 884 00:30:26,450 --> 00:30:28,534 I've got the rough shape on my tip. 885 00:30:28,619 --> 00:30:30,160 I'm going to take it over to the vice, 886 00:30:30,204 --> 00:30:31,870 and I'm gonna start splitting it down the middle. 887 00:30:31,956 --> 00:30:32,996 While my steel's heating, 888 00:30:33,082 --> 00:30:35,207 I might as well be doing something else. 889 00:30:35,292 --> 00:30:36,458 This is gonna be the guard. 890 00:30:36,544 --> 00:30:38,210 I grab the metal that I'm gonna be using 891 00:30:38,295 --> 00:30:39,753 for my pommel and the guard. 892 00:30:39,839 --> 00:30:42,089 I start forging those into the proper dimensions. 893 00:30:42,174 --> 00:30:44,007 Right now I feel like I'm in pretty good shape. 894 00:30:44,093 --> 00:30:45,968 Tomorrow I'm gonna finish grinding the blade 895 00:30:46,011 --> 00:30:48,679 and I'm gonna get it ready for quench. 896 00:30:48,722 --> 00:30:51,348 ♪ ♪ 897 00:30:51,392 --> 00:30:53,517 day two, gonna go through 898 00:30:53,561 --> 00:30:54,893 and trying to get some resemblance 899 00:30:54,979 --> 00:30:56,186 of the final piece. 900 00:30:56,230 --> 00:30:57,563 I'm definitely on schedule, 901 00:30:57,648 --> 00:30:59,648 but there's gonna be a lot of grinding. 902 00:30:59,733 --> 00:31:01,233 As I'm grinding along... 903 00:31:01,318 --> 00:31:02,734 [metal clatters] 904 00:31:02,820 --> 00:31:04,403 [bleep]! 905 00:31:04,446 --> 00:31:06,655 Grinder grabs the top limb of the blade and just snaps it. 906 00:31:06,699 --> 00:31:07,698 [bleep]. 907 00:31:07,741 --> 00:31:09,908 I've got a broke blade now. 908 00:31:09,994 --> 00:31:11,702 I'm already ten hours into this. 909 00:31:11,745 --> 00:31:12,703 [sighs] 910 00:31:12,788 --> 00:31:13,954 what am I gonna do? 911 00:31:14,039 --> 00:31:16,039 [metal clatters] 912 00:31:18,502 --> 00:31:19,710 starting over. 913 00:31:19,795 --> 00:31:22,296 Grab my steel. Get it in the forge right away. 914 00:31:22,381 --> 00:31:26,008 I've got to try and get other work done between heats. 915 00:31:26,093 --> 00:31:27,843 So I'm working on my guard pieces. 916 00:31:27,887 --> 00:31:29,720 I know I'm behind a power curve now. 917 00:31:29,763 --> 00:31:31,388 So I get another one knocked out 918 00:31:31,473 --> 00:31:33,765 in about two hours less time than the first one. 919 00:31:33,851 --> 00:31:35,309 ♪ ♪ 920 00:31:35,394 --> 00:31:36,727 I get it heat-treated. 921 00:31:36,770 --> 00:31:38,812 My guard material is roughed out. 922 00:31:38,898 --> 00:31:42,024 I'm behind, but yet, I still worked ahead. 923 00:31:42,109 --> 00:31:43,859 ♪ ♪ 924 00:31:43,944 --> 00:31:45,485 it's the morning of day two, here. 925 00:31:45,571 --> 00:31:49,573 My goal is to quench before the night is over. 926 00:31:49,658 --> 00:31:53,744 I'm going to make a exact duplicate of my tang. 927 00:31:53,829 --> 00:31:55,370 It's a dead match. 928 00:31:55,456 --> 00:31:58,206 Now I can get to work on my handle. 929 00:31:58,292 --> 00:31:59,416 ♪ ♪ 930 00:31:59,501 --> 00:32:01,084 that's how it should look when it's done. 931 00:32:01,170 --> 00:32:03,712 If it fits on the duplicate, it should fit on the sword. 932 00:32:03,797 --> 00:32:05,714 Time to quench. 933 00:32:05,799 --> 00:32:07,674 ♪ ♪ 934 00:32:07,760 --> 00:32:09,676 it's actually not bad. 935 00:32:09,762 --> 00:32:10,969 Got a lot done today. 936 00:32:11,055 --> 00:32:13,347 Really excited to see where tomorrow brings. 937 00:32:13,432 --> 00:32:15,557 Won't cut yet, but it will. 938 00:32:15,643 --> 00:32:17,309 [heavy rock music] 939 00:32:17,394 --> 00:32:20,354 - yesterday I was able to get the second blade pounded out. 940 00:32:20,439 --> 00:32:24,232 Plan for today is make that cut from the hole to the tip. 941 00:32:24,318 --> 00:32:26,234 This is a butt-puckering moment for me. 942 00:32:26,320 --> 00:32:28,445 If this doesn't work, I'm in deep trouble. 943 00:32:28,530 --> 00:32:31,281 Oh, man, that is way too thin up there. 944 00:32:31,367 --> 00:32:33,033 What can you do? 945 00:32:33,118 --> 00:32:35,494 Now my biggest challenge is the handle and guard. 946 00:32:35,579 --> 00:32:37,579 There's a lot of moving parts with it. 947 00:32:37,665 --> 00:32:40,457 Even though it's a lot of hard work and there's frustration, 948 00:32:40,542 --> 00:32:41,500 I had fun. 949 00:32:41,585 --> 00:32:42,584 That's why we do this craft. 950 00:32:42,670 --> 00:32:45,629 ♪ ♪ 951 00:32:45,673 --> 00:32:47,506 - I'm a little bit short on the tines. 952 00:32:47,591 --> 00:32:49,007 And I don't know where they're measuring to, 953 00:32:49,093 --> 00:32:50,801 so I wanna make sure there's no question 954 00:32:50,886 --> 00:32:52,803 about whether I'm in parameters or not. 955 00:32:52,888 --> 00:32:55,472 Take it over to the drill press and drill my hole bigger. 956 00:32:55,557 --> 00:32:57,391 I'm already dealing with a hardened blade. 957 00:32:57,476 --> 00:32:59,935 So if I get any sort of a wiggle, 958 00:33:00,020 --> 00:33:01,436 I could snap my blade in half. 959 00:33:01,480 --> 00:33:03,021 That would not make me very happy. 960 00:33:03,107 --> 00:33:05,649 I measured again, and we're within parameters. 961 00:33:05,734 --> 00:33:06,817 We're in good shape. 962 00:33:06,902 --> 00:33:09,277 It's time to assemble this thing. 963 00:33:09,363 --> 00:33:11,363 There we go. That's more better, less worse. 964 00:33:11,448 --> 00:33:13,156 ♪ ♪ 965 00:33:13,242 --> 00:33:15,117 now that I have a finished blade, 966 00:33:15,202 --> 00:33:16,952 I have a piece of roast beef. 967 00:33:17,037 --> 00:33:20,872 That is a nice, clean cut right there. 968 00:33:20,958 --> 00:33:23,500 ♪ ♪ 969 00:33:23,585 --> 00:33:25,419 - well, gentlemen, welcome back to the forge. 970 00:33:25,504 --> 00:33:27,295 You guys had four days at your home forges 971 00:33:27,381 --> 00:33:28,880 to work on your serrated tegha swords. 972 00:33:28,966 --> 00:33:30,757 But only one of you will be leaving here 973 00:33:30,843 --> 00:33:32,467 with the title of "forged in fire" champion. 974 00:33:32,553 --> 00:33:34,011 Kevin, how'd your build go? 975 00:33:34,096 --> 00:33:35,762 - I had so much fun that I decided to break it 976 00:33:35,848 --> 00:33:37,264 and start over again. 977 00:33:37,349 --> 00:33:38,724 Went with thicker 5160. 978 00:33:38,809 --> 00:33:40,684 The guard is made out of angle iron, 979 00:33:40,769 --> 00:33:43,145 and the pommel is made out of volkswagen axle. 980 00:33:43,230 --> 00:33:44,771 - That's a quick piece of work, man. 981 00:33:44,857 --> 00:33:46,440 Aric, how'd it go for you? 982 00:33:46,525 --> 00:33:48,483 - Very good. Mine is also 5160. 983 00:33:48,569 --> 00:33:50,861 I got a mild steel guard and pommel, 984 00:33:50,946 --> 00:33:53,739 with rabbit fur for the inside. 985 00:33:53,824 --> 00:33:55,699 - Well, gentlemen, there's only one way to find out 986 00:33:55,743 --> 00:33:57,492 if these blades are as deadly as they look, 987 00:33:57,578 --> 00:33:58,618 and that's with a couple tests. 988 00:33:58,704 --> 00:34:00,996 And up first, the keal. Doug. 989 00:34:01,081 --> 00:34:02,831 ♪ ♪ 990 00:34:02,916 --> 00:34:05,625 - bladesmiths, welcome to the keal test. 991 00:34:05,711 --> 00:34:07,169 Let's find out 992 00:34:07,254 --> 00:34:09,421 what kind of lethal damage your serrated tegha will do. 993 00:34:09,506 --> 00:34:10,714 Kevin, you're up first. You ready? 994 00:34:10,799 --> 00:34:12,132 - Ready as I'll ever be. 995 00:34:12,217 --> 00:34:13,425 - Let's do this. 996 00:34:13,510 --> 00:34:15,302 - As doug is getting ready to do the keal test, 997 00:34:15,387 --> 00:34:17,179 I can feel my heart rate is increasing. 998 00:34:17,264 --> 00:34:19,014 Is there a flaw in there anywhere? 999 00:34:19,099 --> 00:34:20,223 Did I heat-treat correct? 1000 00:34:20,309 --> 00:34:22,142 So I'm feeling not that confident. 1001 00:34:22,227 --> 00:34:24,061 [heavy metal builds] 1002 00:34:24,146 --> 00:34:26,855 [heavy metal music] 1003 00:34:26,940 --> 00:34:33,904 ♪ ♪ 1004 00:34:39,411 --> 00:34:40,952 [thud echoes, fluid squelches] 1005 00:34:41,038 --> 00:34:42,579 [laughs] 1006 00:34:42,664 --> 00:34:45,415 - all right, kevin, let's talk about your serrated tegha here. 1007 00:34:45,459 --> 00:34:46,792 First up, 1008 00:34:46,877 --> 00:34:48,835 the serrations you have here are indeed very sharp. 1009 00:34:48,921 --> 00:34:50,295 You can feel every cut. 1010 00:34:50,380 --> 00:34:52,380 Now, your handle construction is smooth. 1011 00:34:52,466 --> 00:34:55,092 A little bit on the wider side on this handle, 1012 00:34:55,177 --> 00:34:58,095 but it wasn't an issue in controlling your weapon. 1013 00:34:58,180 --> 00:35:01,223 Overall, sir, your weapon, it will keal. 1014 00:35:01,308 --> 00:35:04,267 All right, aric. You ready to take a look? 1015 00:35:04,311 --> 00:35:06,269 - I'm ready. Let's do it. - All right. 1016 00:35:06,355 --> 00:35:09,272 - Kevin's blade performed absolutely phenomenal. 1017 00:35:09,358 --> 00:35:10,899 I mean, he cut the dummy's head off. 1018 00:35:10,984 --> 00:35:13,443 I've gotta perform at least at that level 1019 00:35:13,487 --> 00:35:15,570 to even have a chance at winning this thing. 1020 00:35:17,616 --> 00:35:24,621 ♪ ♪ 1021 00:35:31,797 --> 00:35:33,421 [exhales] 1022 00:35:33,507 --> 00:35:34,589 - all right, aric. 1023 00:35:34,675 --> 00:35:36,758 The serrations on your sword are sharp. 1024 00:35:36,844 --> 00:35:38,552 When I ripped through the shoulder, 1025 00:35:38,637 --> 00:35:40,095 it cut easily. 1026 00:35:40,180 --> 00:35:42,931 Now, your sword is much lighter. 1027 00:35:43,016 --> 00:35:44,975 It tapers before it gets to the bend, 1028 00:35:45,060 --> 00:35:47,853 making the sword easy to swing one-handed. 1029 00:35:47,938 --> 00:35:51,148 Overall, sir, your weapon, it will keal. 1030 00:35:51,191 --> 00:35:52,274 - Awesome. 1031 00:35:52,359 --> 00:35:54,526 ♪ ♪ 1032 00:35:54,611 --> 00:35:56,778 - all right, gentlemen. Time for the strength test. 1033 00:35:56,864 --> 00:35:58,280 Now, to test the strength 1034 00:35:58,365 --> 00:36:00,115 and overall construction of your blades, 1035 00:36:00,200 --> 00:36:02,617 I will be taking them and smashing these pots. 1036 00:36:02,703 --> 00:36:04,244 Now remember, this is not about 1037 00:36:04,329 --> 00:36:06,454 how well your blades hold up through this punishment. 1038 00:36:06,498 --> 00:36:07,831 Kevin, you're up first. You ready? 1039 00:36:07,875 --> 00:36:09,332 - Yes, sir. - All right. Let's do it. 1040 00:36:12,045 --> 00:36:14,337 Cern is any breakage. 1041 00:36:14,423 --> 00:36:15,839 I already had a blade break. 1042 00:36:15,883 --> 00:36:17,632 I don't wanna see that again. 1043 00:36:17,718 --> 00:36:19,342 [dramatic music] 1044 00:36:19,386 --> 00:36:21,011 - [grunting] 1045 00:36:21,054 --> 00:36:28,018 ♪ ♪ 1046 00:36:30,689 --> 00:36:31,855 [tense music] 1047 00:36:31,899 --> 00:36:35,192 kevin, your handle, it's kind of fat, 1048 00:36:35,277 --> 00:36:36,401 but your distance, 1049 00:36:36,486 --> 00:36:38,695 your scale with your guard is great for me. 1050 00:36:38,780 --> 00:36:40,405 As far as your blade goes, 1051 00:36:40,490 --> 00:36:42,866 I mean, you've taken some pretty big hits 1052 00:36:42,910 --> 00:36:44,784 and lost a lot of the tips of your serrations. 1053 00:36:44,870 --> 00:36:47,662 - Right. - The blade is in one piece. 1054 00:36:47,748 --> 00:36:49,206 It's still solid. Nothing loosened up. 1055 00:36:49,249 --> 00:36:51,041 Well done. - Thank you. 1056 00:36:51,084 --> 00:36:52,918 - All right, aric, ready to get ugly? 1057 00:36:53,003 --> 00:36:54,544 [laughs] - tear it up. 1058 00:36:54,630 --> 00:36:57,422 [intriguing music] 1059 00:36:57,507 --> 00:37:01,051 [guitar chord building] 1060 00:37:01,094 --> 00:37:02,510 - [grunting] 1061 00:37:02,554 --> 00:37:05,555 [heavy metal music] 1062 00:37:05,599 --> 00:37:12,562 ♪ ♪ 1063 00:37:15,275 --> 00:37:17,359 - well, I wasn't expecting sparks. 1064 00:37:17,444 --> 00:37:19,611 - So, aric, right off, up here on your blade, 1065 00:37:19,696 --> 00:37:21,905 you've taken some damage on these serrations. 1066 00:37:21,949 --> 00:37:23,448 You've lost a bit of this edge. 1067 00:37:23,533 --> 00:37:25,909 It's still in one piece. You did a good job. 1068 00:37:25,994 --> 00:37:27,744 Congratulations. - Thank you. 1069 00:37:27,788 --> 00:37:28,787 ♪ ♪ 1070 00:37:28,872 --> 00:37:30,413 - all right, bladesmiths, 1071 00:37:30,499 --> 00:37:32,916 it's time to find out how sharp your blades are. 1072 00:37:33,001 --> 00:37:36,086 This is the sharpness test: The jackfruit slice. 1073 00:37:36,129 --> 00:37:37,420 To find out how sharp your weapons are, 1074 00:37:37,464 --> 00:37:38,755 I'm gonna take your weapon 1075 00:37:38,799 --> 00:37:40,799 to cut the rope and release this jackfruit. 1076 00:37:40,884 --> 00:37:42,592 Then I'm gonna slice through it. 1077 00:37:42,678 --> 00:37:43,927 Now, unlike the strength test, 1078 00:37:43,971 --> 00:37:45,971 this is all about what the edge of your blade 1079 00:37:46,056 --> 00:37:47,931 does to the jackfruit. 1080 00:37:48,016 --> 00:37:49,599 Kevin, you're up first. You ready? 1081 00:37:49,643 --> 00:37:50,684 - Yes, sir. 1082 00:37:50,769 --> 00:37:51,726 - Let's do this. 1083 00:37:51,812 --> 00:37:55,105 [dramatic percussion] 1084 00:37:55,148 --> 00:37:58,650 [music building] 1085 00:37:58,735 --> 00:38:01,778 [heavy metal music] 1086 00:38:01,822 --> 00:38:08,785 ♪ ♪ 1087 00:38:12,291 --> 00:38:13,331 all right, kevin. 1088 00:38:13,417 --> 00:38:14,958 Let's talk about your edge, here. 1089 00:38:15,002 --> 00:38:17,627 So the sweet spot that we have right here for this sword 1090 00:38:17,671 --> 00:38:20,463 took a lot of damage during the strength test. 1091 00:38:20,549 --> 00:38:22,799 So in the initial cut on the rope, 1092 00:38:22,884 --> 00:38:24,259 it didn't cut. 1093 00:38:24,344 --> 00:38:25,552 Now, on the second cut, 1094 00:38:25,637 --> 00:38:27,470 we use a little bit other parts of the blade, 1095 00:38:27,556 --> 00:38:28,805 where it is sharp. 1096 00:38:28,890 --> 00:38:31,266 It cut the rope and it cut the jackfruit. 1097 00:38:31,310 --> 00:38:33,810 So overall, sir, your weapon, it will cut. 1098 00:38:33,854 --> 00:38:34,811 - Good. 1099 00:38:34,896 --> 00:38:36,146 - All right, aric. Your turn, sir. 1100 00:38:36,189 --> 00:38:37,480 You ready? - Let's do it. 1101 00:38:37,524 --> 00:38:44,487 ♪ ♪ 1102 00:38:49,786 --> 00:38:50,910 [tense music] 1103 00:38:50,996 --> 00:38:52,495 - all right, aric. So it's the same thing. 1104 00:38:52,539 --> 00:38:53,997 The sweet spot on this blade 1105 00:38:54,082 --> 00:38:55,915 took some dulling on the strength test, 1106 00:38:56,001 --> 00:38:58,293 and it did affect cutting the rope on the first attempt. 1107 00:38:58,378 --> 00:39:00,337 On the second attempt, cut that rope 1108 00:39:00,380 --> 00:39:02,839 and it also cut the jackfruit in half. 1109 00:39:02,883 --> 00:39:05,175 Overall, sir, your weapon, it will cut. 1110 00:39:05,218 --> 00:39:06,676 - Excellent. 1111 00:39:06,720 --> 00:39:07,802 ♪ ♪ 1112 00:39:07,888 --> 00:39:09,012 - all right, gentlemen, 1113 00:39:09,056 --> 00:39:10,430 well, both your tegha swords performed 1114 00:39:10,515 --> 00:39:11,723 exceptionally well during our tests, 1115 00:39:11,808 --> 00:39:13,058 but the time has come for them to decide 1116 00:39:13,143 --> 00:39:14,642 who will be leaving here 1117 00:39:14,686 --> 00:39:16,519 with the title of "forged in fire" champion 1118 00:39:16,563 --> 00:39:18,855 and that check for $10,000. 1119 00:39:18,940 --> 00:39:19,981 While they deliberate, 1120 00:39:20,067 --> 00:39:21,024 I'm gonna have to ask you to both 1121 00:39:21,109 --> 00:39:22,192 please step off the forge floor. 1122 00:39:22,235 --> 00:39:25,028 ♪ ♪ 1123 00:39:25,072 --> 00:39:26,696 doug, what do you think about the tegha swords? 1124 00:39:26,740 --> 00:39:29,199 - Both swords did very well on the keal test, 1125 00:39:29,284 --> 00:39:31,701 but aric's was just easier to control. 1126 00:39:31,745 --> 00:39:33,661 Kevin's is a little bit heavier. 1127 00:39:33,705 --> 00:39:35,914 The handle, it's just so wide, 1128 00:39:35,999 --> 00:39:37,374 so it opens up my hand. 1129 00:39:37,459 --> 00:39:39,501 Both blades took a lot of damage 1130 00:39:39,586 --> 00:39:40,543 during the strength test, 1131 00:39:40,629 --> 00:39:41,878 but when you look at kevin's, 1132 00:39:41,963 --> 00:39:45,382 his has really taken a big dulling on that spot. 1133 00:39:45,425 --> 00:39:46,383 But they both cut. 1134 00:39:46,468 --> 00:39:47,592 - Well, dave, you're the only one 1135 00:39:47,677 --> 00:39:48,676 who's built one of these things. 1136 00:39:48,762 --> 00:39:50,970 - The damage kevin took, to me, 1137 00:39:51,056 --> 00:39:53,181 indicates that he just didn't get that blade hard. 1138 00:39:53,225 --> 00:39:54,682 The teeth are just rolled off. 1139 00:39:54,768 --> 00:39:55,725 They just got flattened. 1140 00:39:55,811 --> 00:39:57,352 As far as aric's blade goes, 1141 00:39:57,437 --> 00:39:59,187 the damage it took in the blade, 1142 00:39:59,231 --> 00:40:00,188 a little bit of dulling. 1143 00:40:00,273 --> 00:40:02,399 It really deflected a lot 1144 00:40:02,484 --> 00:40:03,900 and came back to true. 1145 00:40:03,944 --> 00:40:05,693 So I think he did a good job on the heat treat 1146 00:40:05,737 --> 00:40:06,945 and the temper on that blade. 1147 00:40:07,030 --> 00:40:09,239 They both performed fairly equally, I think. 1148 00:40:09,324 --> 00:40:10,532 The telling is the damage. 1149 00:40:10,617 --> 00:40:12,575 - Okay. You need to make a decision. 1150 00:40:12,619 --> 00:40:14,661 Dave, you know who you choose? - Yes. 1151 00:40:14,746 --> 00:40:16,704 - J., you make your decision? - Oh, yeah. 1152 00:40:16,790 --> 00:40:18,748 - Doug, how about you? - Yes, I have. 1153 00:40:18,792 --> 00:40:19,916 - All right. We'll call 'em back in. 1154 00:40:19,960 --> 00:40:21,418 ♪ ♪ 1155 00:40:21,461 --> 00:40:22,919 well, gentlemen, we gave you 1156 00:40:22,963 --> 00:40:25,213 an extremely difficult blade to build in the tegha sword, 1157 00:40:25,298 --> 00:40:26,965 and you both performed exceptionally well 1158 00:40:27,050 --> 00:40:28,091 in our tests, 1159 00:40:28,176 --> 00:40:29,592 but the judges have made their decision, 1160 00:40:29,636 --> 00:40:30,802 and there can only be one champion. 1161 00:40:30,887 --> 00:40:32,554 And the "forged in fire" champion today is... 1162 00:40:32,639 --> 00:40:35,223 ♪ ♪ 1163 00:40:35,308 --> 00:40:36,683 aric. Congratulations. 1164 00:40:36,768 --> 00:40:38,393 Kevin, unfortunately, you didn't make the cut, 1165 00:40:38,437 --> 00:40:39,769 and dave's gonna tell you why. 1166 00:40:39,813 --> 00:40:41,479 - Kevin, what this came down to 1167 00:40:41,565 --> 00:40:43,106 was the heat treat in that blade, 1168 00:40:43,191 --> 00:40:44,566 not getting it hard enough, 1169 00:40:44,651 --> 00:40:46,901 and so many of those teeth just got pounded 1170 00:40:46,945 --> 00:40:48,403 back into that blade. 1171 00:40:48,488 --> 00:40:49,612 That's why we're letting you go. 1172 00:40:49,656 --> 00:40:50,822 - Okay. 1173 00:40:50,866 --> 00:40:52,532 - Well, kevin, you did exceptionally well, 1174 00:40:52,617 --> 00:40:54,367 but unfortunately, your time in the forge has ended. 1175 00:40:54,453 --> 00:40:55,743 I'm gonna have to ask you to please step out. 1176 00:40:55,829 --> 00:40:57,120 ♪ ♪ 1177 00:40:57,205 --> 00:40:58,955 - that was probably the most challenging thing 1178 00:40:59,040 --> 00:41:00,290 that I've ever done. 1179 00:41:00,333 --> 00:41:01,291 It had about half a dozen things 1180 00:41:01,376 --> 00:41:02,625 that I'd never done before. 1181 00:41:02,669 --> 00:41:03,960 I gave it my all. 1182 00:41:04,045 --> 00:41:06,254 So I'm pleased with what I've brought to the table. 1183 00:41:06,339 --> 00:41:08,131 And I'm ready to get back at it again. 1184 00:41:08,175 --> 00:41:09,591 ♪ ♪ 1185 00:41:09,634 --> 00:41:10,884 - aric, congratulations. 1186 00:41:10,969 --> 00:41:13,386 You are today's "forged in fire" champion. 1187 00:41:13,472 --> 00:41:15,638 Feeling pretty good? - I'm feeling amazing. 1188 00:41:15,682 --> 00:41:17,474 - You definitely impressed us. Good job, man. 1189 00:41:17,517 --> 00:41:19,976 Without further ado, there is a check for $10,000 1190 00:41:20,061 --> 00:41:21,311 waiting for you out that door. 1191 00:41:21,354 --> 00:41:22,645 Go grab it. - Thank you. 1192 00:41:22,689 --> 00:41:23,813 ♪ ♪ 1193 00:41:23,899 --> 00:41:25,440 [laughing] I don't even know how it happened. 1194 00:41:25,484 --> 00:41:26,524 Oh, man. 1195 00:41:26,610 --> 00:41:28,276 That is-- it's a surreal feeling. 1196 00:41:28,320 --> 00:41:29,694 Still hasn't even kicked in. 1197 00:41:29,779 --> 00:41:31,321 I recently got engaged, 1198 00:41:31,364 --> 00:41:33,406 so I will be putting the $10,000 1199 00:41:33,492 --> 00:41:35,992 towards my wedding and my honeymoon afterwards. 1200 00:41:36,036 --> 00:41:37,160 Love you, baby. 1201 00:41:37,204 --> 00:41:43,833 ♪ ♪