1 00:00:05,047 --> 00:00:08,132 [dramatic music] 2 00:00:08,217 --> 00:00:15,139 ♪ ♪ 3 00:00:17,810 --> 00:00:19,309 - my name is clay wolf. 4 00:00:19,395 --> 00:00:21,937 I build houses for a living, and I'm a part-time bladesmith. 5 00:00:22,023 --> 00:00:24,940 I got into smithing by watching the competition. 6 00:00:25,026 --> 00:00:27,359 So I bought a forge, and then I started 7 00:00:27,403 --> 00:00:30,029 doing my own at-home competitions with myself. 8 00:00:30,072 --> 00:00:31,905 I set a three-hour alarm, 9 00:00:31,991 --> 00:00:34,742 and I make random parameters for myself, 10 00:00:34,827 --> 00:00:35,909 and I go at it. 11 00:00:35,995 --> 00:00:37,911 ♪ ♪ 12 00:00:37,997 --> 00:00:39,371 - my name's chad morton. 13 00:00:39,415 --> 00:00:41,373 I'm a registered nurse and a baptist minister. 14 00:00:41,459 --> 00:00:44,043 Nursing can be very mentally taxing sometime. 15 00:00:44,128 --> 00:00:45,753 So that's what I love about forging-- 16 00:00:45,838 --> 00:00:47,171 I can let the brain go, 17 00:00:47,256 --> 00:00:49,048 get out there, and get a little hammer therapy. 18 00:00:49,133 --> 00:00:50,883 I started watching "forged in fire" with the kids, 19 00:00:50,926 --> 00:00:52,342 and they loved it, and they kept asking, 20 00:00:52,428 --> 00:00:54,845 "dad, when are you gonna go on?" 21 00:00:54,930 --> 00:00:56,513 ♪ ♪ 22 00:00:56,599 --> 00:00:57,973 - my name is andrew cole glaser. 23 00:00:58,059 --> 00:00:59,850 I'm a part-time bladesmith, 24 00:00:59,935 --> 00:01:02,144 and I'm also a volunteer fireman for the community. 25 00:01:02,229 --> 00:01:03,896 If I win, that'd be awesome. 26 00:01:03,981 --> 00:01:05,522 I can use $10,000... 27 00:01:05,608 --> 00:01:08,358 After I get an okay from my wife about how I use I. 28 00:01:08,444 --> 00:01:09,777 I'm a kept man. 29 00:01:09,862 --> 00:01:11,695 What I do is what my wife tells me to do. 30 00:01:11,781 --> 00:01:13,363 If she says, "build a fence," I build a fence. 31 00:01:13,449 --> 00:01:15,532 If she says, "build a house," I build a house. 32 00:01:15,618 --> 00:01:17,409 And if she says, "go on 'forged in fire,'" 33 00:01:17,453 --> 00:01:19,203 I go on "forged in fire." 34 00:01:19,288 --> 00:01:21,205 ♪ ♪ 35 00:01:21,290 --> 00:01:23,248 - I'm devon chatterley. I'm 29 years old. 36 00:01:23,334 --> 00:01:25,709 I am an active national guardsman 37 00:01:25,795 --> 00:01:28,212 and I'm a part-time bladesmith. 38 00:01:28,297 --> 00:01:31,215 I need to come in here gung ho, full focus. 39 00:01:31,300 --> 00:01:33,217 I'm ready to become the next "forged in fire" champion 40 00:01:33,302 --> 00:01:35,469 and join the other winners before me. 41 00:01:35,554 --> 00:01:37,888 ♪ ♪ 42 00:01:37,973 --> 00:01:39,973 - bladesmiths, welcome to the forge. 43 00:01:40,059 --> 00:01:41,100 ♪ ♪ 44 00:01:41,185 --> 00:01:42,810 the four of you are about to take part 45 00:01:42,895 --> 00:01:46,063 in three very intense rounds of forging competition, 46 00:01:46,148 --> 00:01:47,898 where we're gonna put your skills to the test. 47 00:01:47,983 --> 00:01:49,900 At the end of each round, you're gonna present your work 48 00:01:49,985 --> 00:01:52,402 to our panel of expert judges, who will be the ones decidig 49 00:01:52,488 --> 00:01:54,738 which three of you will be leaving the forge empty-handed 50 00:01:54,824 --> 00:01:55,948 and who's gonna be leaving here 51 00:01:56,033 --> 00:01:57,950 with the title of "forged in fire" champion 52 00:01:58,035 --> 00:02:00,744 and a check for $10,000. 53 00:02:00,830 --> 00:02:02,830 The judges for today's competition are... 54 00:02:02,915 --> 00:02:05,332 Abs master smith j. Neilson, 55 00:02:05,417 --> 00:02:08,293 historic weapons re-creation specialist dave baker, 56 00:02:08,379 --> 00:02:10,838 and edge weapon specialist and kali martial artist 57 00:02:10,923 --> 00:02:12,923 doug marcaida. 58 00:02:13,008 --> 00:02:14,174 Now, guys, you might have noticed 59 00:02:14,260 --> 00:02:16,218 that it is absolutely frigid in here. 60 00:02:16,303 --> 00:02:17,886 That's because today in the forge, 61 00:02:17,972 --> 00:02:20,430 we are paying tribute to some cold-weather warriors 62 00:02:20,516 --> 00:02:22,182 who have been fighting the ice for centuries. 63 00:02:22,268 --> 00:02:26,103 This is a competition we are calling arctic forge. 64 00:02:26,188 --> 00:02:27,521 In this first round of competition, 65 00:02:27,606 --> 00:02:29,064 we're gonna ask you to re-create a blade 66 00:02:29,150 --> 00:02:32,317 that has been used by alaskan natives for centuries. 67 00:02:32,403 --> 00:02:34,278 Now, that blade is... 68 00:02:34,363 --> 00:02:38,866 ♪ ♪ 69 00:02:38,951 --> 00:02:40,450 the ulu. 70 00:02:40,536 --> 00:02:42,161 ♪ ♪ 71 00:02:42,246 --> 00:02:44,454 - the ulu is a knife used by the inuit people 72 00:02:44,540 --> 00:02:47,958 of arctic regions of greenland, canada, and alaska. 73 00:02:48,043 --> 00:02:50,502 This versatile blade is extremely practical 74 00:02:50,588 --> 00:02:52,504 for surviving life in the frigid tundra 75 00:02:52,548 --> 00:02:54,715 and can be used for anything from skinning animals 76 00:02:54,800 --> 00:02:57,176 to cutting through ice. 77 00:02:57,261 --> 00:03:00,804 The ulu also holds important cultural value as well. 78 00:03:00,890 --> 00:03:02,973 The inuit people traditionally passed down these knives 79 00:03:03,058 --> 00:03:05,309 from generation to generation, believing that the blades 80 00:03:05,394 --> 00:03:07,978 contained the knowledge of their ancestors. 81 00:03:08,063 --> 00:03:10,564 ♪ ♪ 82 00:03:10,649 --> 00:03:12,107 - when you're building your ulus, 83 00:03:12,193 --> 00:03:14,151 I want you to meet these parameters. 84 00:03:14,236 --> 00:03:16,028 You need to have a crescent-shaped cutting ede 85 00:03:16,113 --> 00:03:18,322 that measures between seven and eight inches. 86 00:03:18,407 --> 00:03:22,826 And you also must have a fully enclosed full tang handle. 87 00:03:22,870 --> 00:03:24,578 Now, you guys are probably thinking, 88 00:03:24,663 --> 00:03:27,206 "what am I gonna make my ulu out of?" 89 00:03:27,249 --> 00:03:29,583 well, that answer lies at your workstations. 90 00:03:29,668 --> 00:03:31,001 ♪ ♪ 91 00:03:31,086 --> 00:03:32,878 on top of your tables, you have a tarp. 92 00:03:32,963 --> 00:03:34,671 Go ahead and remove that for me. 93 00:03:34,757 --> 00:03:39,801 ♪ ♪ 94 00:03:39,887 --> 00:03:41,470 what you guys have there is a great piece 95 00:03:41,555 --> 00:03:44,014 of high-carbon steel in the form of a ball bearing, 96 00:03:44,099 --> 00:03:47,267 but, unfortunately, it's frozen in a block of ice. 97 00:03:47,353 --> 00:03:49,144 Well, we've got a solution for you. 98 00:03:49,230 --> 00:03:50,354 Next to that block of ice, 99 00:03:50,397 --> 00:03:53,023 there is a cylinder of mild steel. 100 00:03:53,108 --> 00:03:54,691 We want you guys to take that mild steel, 101 00:03:54,777 --> 00:03:57,194 make a tool, and break the ball bearing free. 102 00:03:57,279 --> 00:03:58,737 But keep in mind, you cannot use a hammer, 103 00:03:58,781 --> 00:04:01,198 you cannot throw the ice block on the ground. 104 00:04:01,283 --> 00:04:03,325 You have to make a tool, and you have to use that tol 105 00:04:03,410 --> 00:04:05,244 to break your ball bearing free. 106 00:04:05,287 --> 00:04:06,870 Now, in round two of the competition, 107 00:04:06,956 --> 00:04:08,288 you're gonna add handles to your blades, 108 00:04:08,374 --> 00:04:10,040 turning them into fully functioning ulus. 109 00:04:10,125 --> 00:04:12,167 At that point, you're gonna turn them into the judges, 110 00:04:12,253 --> 00:04:14,169 and they'll test for strength and durability 111 00:04:14,255 --> 00:04:16,129 in a moose antler punch. 112 00:04:16,215 --> 00:04:18,048 Then we're gonna check the edge retention 113 00:04:18,133 --> 00:04:19,967 in an alaskan salmon slice. 114 00:04:20,052 --> 00:04:21,426 And you've only got three hours. 115 00:04:21,470 --> 00:04:23,887 Good luck. Your time starts now. 116 00:04:23,973 --> 00:04:25,681 ♪ ♪ 117 00:04:25,766 --> 00:04:28,058 ice cold, boys! 118 00:04:28,143 --> 00:04:29,559 ♪ ♪ 119 00:04:29,645 --> 00:04:31,770 so this is kind of a dual forging competitio, 120 00:04:31,855 --> 00:04:33,730 where they've got to not only build a tool 121 00:04:33,816 --> 00:04:35,065 to get their steel, 122 00:04:35,150 --> 00:04:36,525 then they have to make the ulu itself. 123 00:04:36,610 --> 00:04:37,818 That's gonna be rough. 124 00:04:37,903 --> 00:04:39,778 - I got my mild steel in the forge. 125 00:04:39,863 --> 00:04:41,863 I decide to make a little hammer out of it. 126 00:04:41,949 --> 00:04:42,906 Simple as that. 127 00:04:42,950 --> 00:04:44,449 - Basically, just make a mace. 128 00:04:44,535 --> 00:04:45,951 Make a short mace. 129 00:04:46,036 --> 00:04:47,077 Leave one end of it fat, 130 00:04:47,121 --> 00:04:48,412 draw a little handle onto it. 131 00:04:48,455 --> 00:04:51,248 Whackity, whackity, whackity. 132 00:04:51,333 --> 00:04:53,417 - It's not gonna be perfect. It just needs to be functional. 133 00:04:53,502 --> 00:04:55,085 [dramatically] it's a little hammer! 134 00:04:55,170 --> 00:04:56,253 ♪ ♪ 135 00:04:56,338 --> 00:04:57,546 - easy, psycho! 136 00:04:57,631 --> 00:04:59,464 - [laughs] - there you go. 137 00:04:59,550 --> 00:05:01,300 - Good lord! - There we go. 138 00:05:01,385 --> 00:05:03,677 - Once I see that ball slides around, I grab it 139 00:05:03,762 --> 00:05:05,053 and I run back to the forge. 140 00:05:05,139 --> 00:05:06,179 Whoo! 141 00:05:06,265 --> 00:05:09,266 ♪ ♪ 142 00:05:09,351 --> 00:05:10,976 - my plan with the mild steel is 143 00:05:11,061 --> 00:05:12,728 to forge out a pick. 144 00:05:12,813 --> 00:05:14,646 I just need it to be long enough to hold on to 145 00:05:14,690 --> 00:05:18,233 and have a sharp point so I can really, really attack that ice. 146 00:05:18,319 --> 00:05:20,444 - Andrew went straight for big blu. 147 00:05:20,529 --> 00:05:22,321 That's a smart move. 148 00:05:22,406 --> 00:05:24,573 - I don't like to spend a lot of time running around 149 00:05:24,658 --> 00:05:25,699 when I do these kinds of things. 150 00:05:25,784 --> 00:05:27,326 I like to take my time. 151 00:05:27,369 --> 00:05:28,660 I like to think about what I'm gonna do. 152 00:05:28,746 --> 00:05:30,620 When you're old, you don't have that much energy, 153 00:05:30,706 --> 00:05:32,539 so you need to conserve it. 154 00:05:32,624 --> 00:05:34,124 - Here we go. 155 00:05:34,209 --> 00:05:35,542 - I get the ball bearing out. 156 00:05:35,627 --> 00:05:36,835 It's really cold. 157 00:05:36,879 --> 00:05:38,337 I'm a little worried about that, 158 00:05:38,380 --> 00:05:40,213 but I don't have time to let it warm up or anythin. 159 00:05:40,299 --> 00:05:42,674 I just have to get it into the forge. 160 00:05:42,760 --> 00:05:44,509 - Taking that ball of steel and just throwing it 161 00:05:44,595 --> 00:05:46,636 in the forge is probably not the best idea. 162 00:05:46,722 --> 00:05:47,679 - What could happen? 163 00:05:47,765 --> 00:05:49,222 - It could shock it, fracture it 164 00:05:49,308 --> 00:05:51,224 to the point where you can't even fix it. 165 00:05:51,310 --> 00:05:53,435 ♪ ♪ 166 00:05:53,520 --> 00:05:55,479 - my plan is to make a small hammer 167 00:05:55,564 --> 00:05:58,648 out of the mild steel and go right at it. 168 00:05:58,734 --> 00:06:01,234 I need to get my ball bearing out of the ice quickly. 169 00:06:01,320 --> 00:06:04,863 52100, it takes a long time to heat up. 170 00:06:04,948 --> 00:06:08,533 - Clay is on the ice block, and it's working pretty quick. 171 00:06:08,619 --> 00:06:11,119 - I broke out my ball bearing relatively fast. 172 00:06:11,205 --> 00:06:12,913 I'm feeling really good right now. 173 00:06:12,998 --> 00:06:15,290 ♪ ♪ 174 00:06:15,376 --> 00:06:17,167 - coming to the forge is a little intimidating, 175 00:06:17,252 --> 00:06:19,753 to, you know, come to these tools I'm not familiar with. 176 00:06:19,838 --> 00:06:21,213 Getting there. 177 00:06:21,298 --> 00:06:22,881 I'm gonna take this piece of mild steel, 178 00:06:22,966 --> 00:06:24,633 and I'm gonna forge it into a little wedge axe head 179 00:06:24,718 --> 00:06:26,426 and just start whacking at it. 180 00:06:26,512 --> 00:06:28,261 ♪ ♪ 181 00:06:28,347 --> 00:06:30,472 - well, you see on his ice block there, 182 00:06:30,557 --> 00:06:33,225 how it's got those big fractures running through it? 183 00:06:33,268 --> 00:06:34,476 Attack the fracture. 184 00:06:34,561 --> 00:06:36,019 You attack the fracture, 185 00:06:36,105 --> 00:06:38,313 and it'll spread through the entire thing. 186 00:06:38,399 --> 00:06:40,649 - It's just taking forever. [sighs deeply] 187 00:06:40,734 --> 00:06:42,526 and it's just beating my hand up. 188 00:06:42,611 --> 00:06:44,694 - Chad's getting close to almost a half an hour 189 00:06:44,780 --> 00:06:48,198 of just trying to get this ball out of the block of ice. 190 00:06:48,283 --> 00:06:50,075 - There we go. - There we go! 191 00:06:50,160 --> 00:06:52,452 - Finally, lo and behold, it's free. 192 00:06:52,538 --> 00:06:53,912 But I'm so tired. 193 00:06:53,956 --> 00:06:55,705 I'm a little bit further behind everybody els, 194 00:06:55,791 --> 00:06:57,290 but think I might still be okay. 195 00:06:57,376 --> 00:06:58,875 I'm gonna get this done no matter what. 196 00:06:58,961 --> 00:07:00,460 ♪ ♪ 197 00:07:00,546 --> 00:07:02,629 - whoo-whee! You look purty hot! 198 00:07:02,714 --> 00:07:04,381 I pull out the ball bearing. 199 00:07:04,466 --> 00:07:05,757 I think that it's hot enough. 200 00:07:05,843 --> 00:07:07,426 As I do the first press, 201 00:07:07,511 --> 00:07:09,094 I just hear it stalling on me. 202 00:07:09,179 --> 00:07:11,721 - Look how cold devon's ball bearing is. 203 00:07:11,765 --> 00:07:13,265 - It's not hot enough. 204 00:07:13,308 --> 00:07:14,724 - That's the one thing you don't want to do. 205 00:07:14,810 --> 00:07:16,017 - Stressing it out. 206 00:07:16,103 --> 00:07:17,769 - That is a lot of steel. 207 00:07:17,813 --> 00:07:19,354 I've already wasted so much time, 208 00:07:19,440 --> 00:07:20,897 so I come to the quick decision. 209 00:07:20,983 --> 00:07:22,524 I'm like, "you know what? I can lose some of it." 210 00:07:22,609 --> 00:07:24,401 - he's gonna be there for the rest of the challenge. 211 00:07:24,486 --> 00:07:26,695 - Yeah. - Those are solid. 212 00:07:26,780 --> 00:07:28,280 - I severely underestimated 213 00:07:28,365 --> 00:07:31,199 how cold and how big this ball bearing is. 214 00:07:31,285 --> 00:07:33,702 This is not working, so I just figured, 215 00:07:33,787 --> 00:07:35,912 "I'm gonna go stick it back in the forge, heat it up again, 216 00:07:35,998 --> 00:07:37,539 "and just take this a little bit at a time 217 00:07:37,624 --> 00:07:39,249 and just be patient." 218 00:07:39,334 --> 00:07:41,668 I finally get it hot enough, and I finally cut it through. 219 00:07:41,753 --> 00:07:43,003 ♪ ♪ 220 00:07:43,088 --> 00:07:44,546 finally! 221 00:07:44,590 --> 00:07:46,423 I got to heat it back up, and I got to start moving metal 222 00:07:46,508 --> 00:07:47,382 faster than ever now. 223 00:07:47,468 --> 00:07:48,925 Time is super against me. 224 00:07:49,011 --> 00:07:51,386 ♪ ♪ 225 00:07:51,472 --> 00:07:54,890 - right now I'm just working on flattening out the stock 226 00:07:54,975 --> 00:07:57,267 so that I'll have enough area, enough space 227 00:07:57,352 --> 00:07:59,644 to start working in a blade form. 228 00:07:59,730 --> 00:08:01,688 - Andrew's also got a nice piece 229 00:08:01,773 --> 00:08:04,941 of a nice wide billet right now. 230 00:08:05,027 --> 00:08:06,359 - Now that I'm done drawing this thing out, 231 00:08:06,445 --> 00:08:09,112 I know that it's way bigger than I need for this ulu, 232 00:08:09,198 --> 00:08:10,447 so it's time to cut it down. 233 00:08:10,532 --> 00:08:11,573 ♪ ♪ 234 00:08:11,658 --> 00:08:12,782 at this point in the round, 235 00:08:12,868 --> 00:08:15,118 I know that I've probably done things right, 236 00:08:15,204 --> 00:08:17,954 but the clock is really ticking down. 237 00:08:18,040 --> 00:08:20,207 I still have to draw out what I have left 238 00:08:20,292 --> 00:08:22,626 into the general shape of an ulu, 239 00:08:22,711 --> 00:08:25,045 which means I still have a lot of forging to do. 240 00:08:25,130 --> 00:08:27,506 ♪ ♪ 241 00:08:27,549 --> 00:08:30,050 - this ball bearing is way too much steel for this ulu, 242 00:08:30,135 --> 00:08:32,302 so my plan is, draw it out, 243 00:08:32,387 --> 00:08:33,678 take it over to the chop saw, 244 00:08:33,764 --> 00:08:35,555 cut some of it off, and I get it thinner. 245 00:08:35,641 --> 00:08:37,390 Otherwise, I'm working a lot of extra steel 246 00:08:37,476 --> 00:08:38,808 that I'm not gonna use. 247 00:08:38,894 --> 00:08:40,352 - Well, chad's making some progress. 248 00:08:40,437 --> 00:08:41,728 Definitely lagging behind a little. 249 00:08:41,813 --> 00:08:43,647 - So my plan is to draw this out 250 00:08:43,732 --> 00:08:46,691 to 1/2 inch thick before I take it over to the chop saw. 251 00:08:46,777 --> 00:08:48,235 Huh... 252 00:08:48,320 --> 00:08:49,736 I'm trying to cut through the bearing. 253 00:08:49,821 --> 00:08:51,655 It's cutting about halfway through it. 254 00:08:51,740 --> 00:08:53,198 - Come on. 255 00:08:53,283 --> 00:08:56,326 - I finally get the good sense to turn it upright. 256 00:08:56,411 --> 00:08:58,662 It cuts through it like a dream, slow and steady. 257 00:08:58,747 --> 00:09:02,040 I am relieved to be done with the stupid chop saw. 258 00:09:02,084 --> 00:09:04,751 - Bladesmiths, you guys are halfway through round one! 259 00:09:04,836 --> 00:09:07,337 You've got an hour and 30 minutes remaining! 260 00:09:07,422 --> 00:09:08,630 ♪ ♪ 261 00:09:08,715 --> 00:09:10,006 what is it about the ulu 262 00:09:10,092 --> 00:09:11,967 that makes this such a difficult blade to make? 263 00:09:12,052 --> 00:09:15,720 - Having to actually wrap this all the way around and make it 264 00:09:15,806 --> 00:09:18,515 one solid homogenous piece of steel is tricky, 265 00:09:18,600 --> 00:09:19,975 and not a lot of smiths do it. 266 00:09:20,060 --> 00:09:21,643 - This blade is very unique 267 00:09:21,728 --> 00:09:23,603 because the handle is on top of the blade 268 00:09:23,689 --> 00:09:25,730 instead of off to the side. 269 00:09:25,774 --> 00:09:27,566 It's gonna be difficult putting a handle on. 270 00:09:27,609 --> 00:09:29,276 It's gonna be difficult getting the shape there. 271 00:09:29,361 --> 00:09:30,735 Come on. 272 00:09:30,821 --> 00:09:33,738 I'm going to draw a handle out the side, 273 00:09:33,782 --> 00:09:35,657 and then fold it back around onto itself 274 00:09:35,742 --> 00:09:37,742 and weld it in place. 275 00:09:37,828 --> 00:09:40,245 - They don't actually need to make, per se, 276 00:09:40,330 --> 00:09:41,955 a blade starting out. 277 00:09:42,040 --> 00:09:44,708 Just take that ball bearing, draw it out into a sheet, 278 00:09:44,793 --> 00:09:46,918 and then cut it out, torch it out, grind it ou, 279 00:09:47,004 --> 00:09:48,461 however you want to do it. 280 00:09:48,547 --> 00:09:50,088 ♪ ♪ 281 00:09:50,173 --> 00:09:52,591 - I'm struggling with how I want to fold it over 282 00:09:52,676 --> 00:09:54,217 to make it look like the ulu. 283 00:09:54,303 --> 00:09:57,262 [sighs] shoot, shoot, shoot. 284 00:09:57,347 --> 00:09:59,764 - It looks like clay is trying to get that tang up 285 00:09:59,850 --> 00:10:01,933 to one side or the other, and it's having trouble. 286 00:10:02,019 --> 00:10:03,602 It's kind of stuck in the middle. 287 00:10:03,687 --> 00:10:06,771 - I eventually get the uprights in the place I wanted them to 288 00:10:06,857 --> 00:10:09,566 so I can bend the top down right where I needed it, 289 00:10:09,651 --> 00:10:11,401 and got them forge welded. 290 00:10:11,445 --> 00:10:13,403 I'm feeling really good right now. 291 00:10:13,488 --> 00:10:15,780 ♪ ♪ 292 00:10:15,824 --> 00:10:17,115 - I'm looking at my steel. 293 00:10:17,200 --> 00:10:18,783 I'm getting the basic shape I need. 294 00:10:18,869 --> 00:10:20,243 Now I just got to figure out, 295 00:10:20,329 --> 00:10:23,413 how am I going to attack getting a hole in this thing 296 00:10:23,498 --> 00:10:25,457 for a hand to sit comfortably in? 297 00:10:25,500 --> 00:10:28,168 I decide I'm gonna have to cut it on the angle grinde. 298 00:10:28,253 --> 00:10:29,669 - I'd still prefer to use the hot wrench 299 00:10:29,755 --> 00:10:30,920 and just blow the hole out. 300 00:10:31,006 --> 00:10:32,756 - It seems like it'd be the fastest. 301 00:10:32,841 --> 00:10:34,299 - I've been wasting so much time 302 00:10:34,384 --> 00:10:35,717 just trying to get this hole out. 303 00:10:35,802 --> 00:10:36,926 I know the time's counting down. 304 00:10:37,012 --> 00:10:38,345 I've been trying to avoid 305 00:10:38,430 --> 00:10:40,013 cutting through the bridge of this handle, 306 00:10:40,098 --> 00:10:41,598 but it comes to the point where 307 00:10:41,642 --> 00:10:44,434 I need to cut through this handle. 308 00:10:44,519 --> 00:10:45,977 It will completely just ruin 309 00:10:46,063 --> 00:10:48,521 the integrity of the blade, in my opinion. 310 00:10:48,607 --> 00:10:50,482 I finally get the piece I need off. 311 00:10:50,567 --> 00:10:52,233 [sighs] finally. 312 00:10:52,319 --> 00:10:53,902 - Devon's back at the welder. 313 00:10:53,987 --> 00:10:55,028 He's putting that chunk 314 00:10:55,113 --> 00:10:56,488 of handle material that he cut off-- 315 00:10:56,573 --> 00:10:58,406 he's welding that back on now. 316 00:10:58,492 --> 00:11:00,575 - The one thing about putting holes into this piece 317 00:11:00,661 --> 00:11:03,495 is that it's got to have enough space 318 00:11:03,580 --> 00:11:04,829 from the knuckles. 319 00:11:04,873 --> 00:11:06,122 Not tiny. 320 00:11:06,208 --> 00:11:08,041 A lot of space. 321 00:11:08,126 --> 00:11:10,794 - It looks good to me. I'm happy with it. 322 00:11:10,879 --> 00:11:13,463 - Bladesmiths, you have one hour remaining! 323 00:11:13,548 --> 00:11:15,799 ♪ ♪ 324 00:11:15,842 --> 00:11:17,926 - to get the shape that I want, 325 00:11:18,011 --> 00:11:20,637 my plan right now is to draw out this tang, 326 00:11:20,722 --> 00:11:22,263 curl it over, and weld it. 327 00:11:22,349 --> 00:11:24,516 - I think what chad's trying to do is what clay did 328 00:11:24,601 --> 00:11:27,310 and loop it around and make a continuous circle. 329 00:11:27,396 --> 00:11:30,188 - I'm hammering this, and I'm not able to draw it out enough 330 00:11:30,232 --> 00:11:32,065 because it's such tough stuff to work 331 00:11:32,150 --> 00:11:33,608 and my hand's already shot from the ice. 332 00:11:33,694 --> 00:11:34,984 [exhales weakly] 333 00:11:35,070 --> 00:11:37,696 I'm pouring sweat. I'm exhausted. 334 00:11:37,781 --> 00:11:39,280 - Does chad look really pale to you guys? 335 00:11:39,366 --> 00:11:40,615 - Yeah, he does. 336 00:11:40,701 --> 00:11:42,117 - When I finally got the ball bearing out, 337 00:11:42,202 --> 00:11:44,411 I've already used all my energy. 338 00:11:44,496 --> 00:11:46,037 - Now we got the medic moving in. 339 00:11:46,123 --> 00:11:47,414 - How you feeling? 340 00:11:47,499 --> 00:11:49,499 - I'm--I'm a little winded, man. 341 00:11:49,584 --> 00:11:51,084 Physically, I'm exhausted. 342 00:11:51,169 --> 00:11:52,252 I don't know if I can keep going. 343 00:11:52,337 --> 00:11:53,795 Oh, man. 344 00:11:58,552 --> 00:11:59,676 I'm pouring sweat. I'm exhausted. 345 00:11:59,761 --> 00:12:00,677 Uh, I'm exhausted, but I'm all right. 346 00:12:00,762 --> 00:12:01,678 - Okay. All right. 347 00:12:01,763 --> 00:12:03,054 - There's no way I'm giving up, 348 00:12:03,140 --> 00:12:05,140 because my kids are counting on me to do my best. 349 00:12:05,225 --> 00:12:06,349 So what do I think? 350 00:12:06,435 --> 00:12:08,852 What does any redneck think? 351 00:12:08,895 --> 00:12:10,562 Angle grinder. 352 00:12:10,605 --> 00:12:12,480 - He's cutting an angle down this way, 353 00:12:12,566 --> 00:12:14,023 and then he's gonna cut across it. 354 00:12:14,109 --> 00:12:16,443 If he heats that whole tang up, 355 00:12:16,528 --> 00:12:18,737 he can squash it down to be something to hold on to. 356 00:12:18,780 --> 00:12:21,364 - But he's still got a triangular point 357 00:12:21,450 --> 00:12:23,074 that's gonna to be hitting your palm, 358 00:12:23,118 --> 00:12:25,201 so he's gonna have to flatten that out. 359 00:12:25,287 --> 00:12:27,078 - I know it's uglier than si, but I'm still 360 00:12:27,164 --> 00:12:29,038 gonna turn in something that meets parameters. 361 00:12:29,082 --> 00:12:31,583 [rock music] 362 00:12:31,668 --> 00:12:34,586 - I notice that my handle tang got too thin 363 00:12:34,629 --> 00:12:36,045 for what I wanted, 364 00:12:36,131 --> 00:12:39,215 but I don't have time to fix that right now. 365 00:12:39,301 --> 00:12:41,176 - If you notice, he's got a lot of blade 366 00:12:41,261 --> 00:12:43,344 and a long, spindly little handle. 367 00:12:43,430 --> 00:12:44,929 Now, that's gonna roll on your hand 368 00:12:44,973 --> 00:12:47,932 if he doesn't build that up with a lot of handle material. 369 00:12:47,976 --> 00:12:50,226 - I feel my blade, and I notice, 370 00:12:50,312 --> 00:12:52,771 right where the handle connects to the blade, 371 00:12:52,856 --> 00:12:54,773 that there is some sharp corners, 372 00:12:54,858 --> 00:12:56,274 and you don't want sharp corners 373 00:12:56,359 --> 00:12:58,610 because that could cause a stress fracture. 374 00:12:58,653 --> 00:13:01,196 So I got to fill it with some weld. 375 00:13:01,281 --> 00:13:02,405 - That's definitely a smart move. 376 00:13:02,491 --> 00:13:06,451 ♪ ♪ 377 00:13:06,536 --> 00:13:09,078 - I'm really liking the overall shape of this blade. 378 00:13:09,164 --> 00:13:11,456 And now it's time to move on to punching the hole through it 379 00:13:11,500 --> 00:13:12,749 for the user's hand. 380 00:13:12,834 --> 00:13:14,167 - Looking at andrew's blade, 381 00:13:14,252 --> 00:13:16,044 I think his shape is really nice. 382 00:13:16,129 --> 00:13:18,379 It's just very, very tall. 383 00:13:18,465 --> 00:13:21,007 - Yeah, and having that hole being that size, 384 00:13:21,092 --> 00:13:22,342 if you're going to hit something, 385 00:13:22,427 --> 00:13:24,010 it can flop one way or the other, 386 00:13:24,095 --> 00:13:25,303 depending on the handle construction, 387 00:13:25,388 --> 00:13:26,805 and really mess your hand up. 388 00:13:26,890 --> 00:13:28,723 - The problem with having corners the way I cut them 389 00:13:28,809 --> 00:13:30,975 is that when you quench the blade, 390 00:13:31,019 --> 00:13:33,686 those are stress risers, and it could create a crack 391 00:13:33,772 --> 00:13:35,396 that just completely ruins the edge. 392 00:13:35,482 --> 00:13:37,941 I make the decision to go ahead and weld up the corners, 393 00:13:38,026 --> 00:13:40,151 because I know that if the blade cracks, 394 00:13:40,237 --> 00:13:43,112 welding that will just not work at all. 395 00:13:43,198 --> 00:13:45,114 - All right, guys, we're coming down to the wire! 396 00:13:45,200 --> 00:13:47,826 You have 30 minutes left on the clock! 397 00:13:47,869 --> 00:13:49,619 Devon's actually turned out all right. 398 00:13:49,704 --> 00:13:50,954 - Yeah. 399 00:13:51,039 --> 00:13:52,664 - As I'm getting ready to quench, 400 00:13:52,707 --> 00:13:54,207 I want to make sure I'm only focusing on the edge 401 00:13:54,292 --> 00:13:56,209 that gets hot and not the rest of the material. 402 00:13:56,294 --> 00:13:58,294 If any of the rest of material gets hot, 403 00:13:58,380 --> 00:14:00,004 I don't know what way it can warp, 404 00:14:00,048 --> 00:14:03,174 and I am not prepared for that or have the time to fix tha. 405 00:14:03,218 --> 00:14:05,051 I need this thing to go perfect. 406 00:14:05,136 --> 00:14:07,637 ♪ ♪ 407 00:14:07,722 --> 00:14:09,931 whoo! - And only quenching the edge. 408 00:14:10,016 --> 00:14:11,099 Smart move. - Nice! 409 00:14:11,184 --> 00:14:12,976 - Good for him. - Smart. 410 00:14:13,061 --> 00:14:15,144 - Lo and behold, no warps. Straight as an arrow. 411 00:14:15,230 --> 00:14:16,855 Now I just need to make sure this sits comfortably 412 00:14:16,940 --> 00:14:19,148 and looks better than it does right now. 413 00:14:19,234 --> 00:14:21,818 ♪ ♪ 414 00:14:21,903 --> 00:14:23,862 - I'm getting ready to quench, and I realize 415 00:14:23,905 --> 00:14:26,322 that I really have forged the blade pretty thin. 416 00:14:26,408 --> 00:14:28,408 And that could create warping. 417 00:14:28,493 --> 00:14:30,952 ♪ ♪ 418 00:14:31,037 --> 00:14:32,620 - andrew's in the quench. 419 00:14:32,706 --> 00:14:35,290 - After the quench, I clamp the thing into the vise. 420 00:14:35,375 --> 00:14:37,876 When you do that, it helps to straighten everything ou. 421 00:14:37,919 --> 00:14:39,460 I pull it out of the vise. 422 00:14:39,546 --> 00:14:40,545 The blade is straight. 423 00:14:40,630 --> 00:14:43,006 I'm pretty happy about how that came out. 424 00:14:43,049 --> 00:14:45,842 - Gentlemen, 15 minutes! 425 00:14:45,927 --> 00:14:51,222 ♪ ♪ 426 00:14:51,266 --> 00:14:52,390 edge quench. 427 00:14:52,475 --> 00:14:54,767 - My blade is straight, and it's hard. 428 00:14:54,853 --> 00:14:56,978 And now I'm off to the grinder. 429 00:14:57,063 --> 00:14:58,688 I need to clean up my blade. 430 00:14:58,773 --> 00:14:59,522 I look down. 431 00:14:59,608 --> 00:15:00,815 ♪ ♪ 432 00:15:02,193 --> 00:15:03,484 there's a crack. 433 00:15:03,570 --> 00:15:05,653 No, no, no, no. No, no, no. - Ooh. 434 00:15:05,739 --> 00:15:08,740 - I don't have time to fix this in the forge, 435 00:15:08,825 --> 00:15:11,034 so I run over to the welder 436 00:15:11,119 --> 00:15:15,204 and I put a bead of weld along the crack. 437 00:15:15,290 --> 00:15:16,664 - You know, it really makes you wonder 438 00:15:16,750 --> 00:15:19,751 how the ball bearing steel 439 00:15:19,836 --> 00:15:22,378 encased in ice and then thrown into fire 440 00:15:22,422 --> 00:15:23,796 has affected that steel. 441 00:15:23,882 --> 00:15:26,257 You gave them time to start to crack the ice open, 442 00:15:26,343 --> 00:15:29,552 but nobody had the patience to warm it up. 443 00:15:29,638 --> 00:15:31,721 - All right, guys, you got five minutes left! 444 00:15:31,806 --> 00:15:33,097 ♪ ♪ 445 00:15:33,183 --> 00:15:34,515 - I got a hole cut in this thing already, 446 00:15:34,601 --> 00:15:36,517 but what I'm trying to do right now is widen that hole 447 00:15:36,603 --> 00:15:38,728 so it's more comfortable for somebody to grip as a handle. 448 00:15:38,813 --> 00:15:42,315 But it's not doing what I want it to do. 449 00:15:42,400 --> 00:15:43,566 - There's an opening about yea big. 450 00:15:43,652 --> 00:15:44,525 - I know. 451 00:15:44,611 --> 00:15:46,736 - Like, 2 1/2-, 3-inch triangle. 452 00:15:46,821 --> 00:15:47,737 - I'm shaking. 453 00:15:47,781 --> 00:15:49,113 I'm just shot, 454 00:15:49,157 --> 00:15:51,658 but I need to get it quenched. 455 00:15:51,743 --> 00:15:53,701 ♪ ♪ 456 00:15:53,787 --> 00:15:55,745 - chad just quenched. 457 00:15:55,789 --> 00:15:58,289 - So now I'm gonna try to do a little bit of rough grinding 458 00:15:58,333 --> 00:15:59,958 to make it look a little less ugly. 459 00:16:00,001 --> 00:16:01,167 Even though I'm exhausted, 460 00:16:01,252 --> 00:16:03,461 I need to suck it up and get it done. 461 00:16:03,505 --> 00:16:04,963 ♪ ♪ 462 00:16:05,048 --> 00:16:07,256 - five, four, 463 00:16:07,300 --> 00:16:10,051 three, two, one! 464 00:16:10,136 --> 00:16:11,970 Gentlemen, turn off your machines! 465 00:16:12,055 --> 00:16:13,304 Put down your tools! 466 00:16:13,348 --> 00:16:15,264 This round is over! 467 00:16:15,350 --> 00:16:17,517 - [whistles] - well done! 468 00:16:17,602 --> 00:16:19,102 ♪ ♪ 469 00:16:19,187 --> 00:16:20,687 - at the end of the round, I feel accomplished. 470 00:16:20,772 --> 00:16:22,480 Even though I know I've made a lot of mistakes, 471 00:16:22,565 --> 00:16:24,482 I feel good that I put my best effort in. 472 00:16:24,526 --> 00:16:26,317 I did my best. I finished. 473 00:16:26,361 --> 00:16:28,194 Pretty sure I met parameters. [chuckles] 474 00:16:28,279 --> 00:16:31,114 ♪ ♪ 475 00:16:31,199 --> 00:16:33,157 - well, bladesmiths, in this first round of competitio, 476 00:16:33,243 --> 00:16:35,326 we were not nice to you. 477 00:16:35,412 --> 00:16:36,703 You should all be proud of your work, 478 00:16:36,788 --> 00:16:38,997 but the time has come for the judges to decide 479 00:16:39,040 --> 00:16:40,498 which three of you will be moving forward 480 00:16:40,542 --> 00:16:41,916 in this competition. 481 00:16:42,002 --> 00:16:44,627 So, clay, are you ready? - Yes, sir. 482 00:16:44,713 --> 00:16:46,212 - Please present your work. 483 00:16:46,297 --> 00:16:48,631 ♪ ♪ 484 00:16:48,717 --> 00:16:50,925 - all right, clay, the thing about an ulu, 485 00:16:51,011 --> 00:16:52,677 when it meets resistance, 486 00:16:52,721 --> 00:16:54,178 it can move around. 487 00:16:54,264 --> 00:16:55,930 If you move to the second round, 488 00:16:56,016 --> 00:16:57,306 you need to address that. 489 00:16:57,392 --> 00:16:59,308 Right now it's not comfortable to hold on to 490 00:16:59,352 --> 00:17:01,853 'cause it's just very narrow. 491 00:17:01,896 --> 00:17:04,272 Also, at the corner of your blade here, 492 00:17:04,357 --> 00:17:07,025 you have a crack that needs to be addressed. 493 00:17:07,068 --> 00:17:08,317 But you do have a good shape. 494 00:17:08,403 --> 00:17:09,318 Good job. 495 00:17:09,404 --> 00:17:10,945 ♪ ♪ 496 00:17:11,031 --> 00:17:12,989 - all right, chad, please present your work. 497 00:17:13,074 --> 00:17:14,991 ♪ ♪ 498 00:17:15,076 --> 00:17:17,201 - all right, chad, this is that ulu-shaped blade 499 00:17:17,245 --> 00:17:18,995 that I was looking to see. 500 00:17:19,080 --> 00:17:20,747 But as it stands right now, 501 00:17:20,832 --> 00:17:23,958 your handle is not really a functional handle. 502 00:17:24,044 --> 00:17:25,918 If you were to move forward, 503 00:17:26,004 --> 00:17:27,670 this would have to be addressed. 504 00:17:27,756 --> 00:17:29,005 It has to be ergonomic. 505 00:17:29,090 --> 00:17:30,882 You have to be able to hang on to it. 506 00:17:30,967 --> 00:17:32,425 And right now that's the biggest issue. 507 00:17:32,510 --> 00:17:33,885 ♪ ♪ 508 00:17:33,928 --> 00:17:36,929 - andrew, you're up next. Please present your work. 509 00:17:37,015 --> 00:17:39,557 ♪ ♪ 510 00:17:39,642 --> 00:17:42,060 - andrew, first off, I love the weight of this thing. 511 00:17:42,145 --> 00:17:44,228 That being said, though, 512 00:17:44,272 --> 00:17:46,147 you've got a hole right here 513 00:17:46,232 --> 00:17:48,900 with a crack going 2/3 of the way down. 514 00:17:48,943 --> 00:17:51,069 And on the other side, you've got one 515 00:17:51,112 --> 00:17:53,404 that's maybe about 1/8 of an inch. 516 00:17:53,448 --> 00:17:54,864 If you don't take care of those cracks, 517 00:17:54,908 --> 00:17:56,365 it might just snap completely. 518 00:17:56,409 --> 00:17:57,992 But I like the shape. 519 00:17:58,078 --> 00:17:59,202 I like the weight. Nice job. 520 00:17:59,287 --> 00:18:00,787 ♪ ♪ 521 00:18:00,872 --> 00:18:03,414 - all right, devon, your turn. Let's see your ulu. 522 00:18:03,458 --> 00:18:05,875 ♪ ♪ 523 00:18:05,919 --> 00:18:08,086 - all right, devon. 524 00:18:08,129 --> 00:18:09,545 Bingo! Good job. 525 00:18:09,589 --> 00:18:11,047 That's what we're looking for. 526 00:18:11,091 --> 00:18:13,591 The only concerns I have are, 527 00:18:13,676 --> 00:18:16,636 if I put my hand in here and squeeze hard, 528 00:18:16,721 --> 00:18:18,596 it's digging into both those fingers. 529 00:18:18,681 --> 00:18:20,932 So having a little bit more room in here 530 00:18:21,017 --> 00:18:22,433 would really be helpful. 531 00:18:22,477 --> 00:18:24,727 But other than that, I think you did a great job. 532 00:18:24,813 --> 00:18:26,062 Nicely done. - Thank you. 533 00:18:26,147 --> 00:18:27,688 ♪ ♪ 534 00:18:27,774 --> 00:18:29,899 - well, gentlemen, we gave you guys a hard task in round one, 535 00:18:29,984 --> 00:18:31,984 but you fought through the cold, and you battled the ice, 536 00:18:32,070 --> 00:18:34,153 and you all came within parameters. 537 00:18:34,239 --> 00:18:36,572 Three of you are moving forward in this competition. 538 00:18:36,658 --> 00:18:37,949 The judges have made their decision. 539 00:18:38,034 --> 00:18:39,742 The bladesmith leaving the forge is... 540 00:18:39,828 --> 00:18:43,204 ♪ ♪ 541 00:18:43,289 --> 00:18:44,622 chad. 542 00:18:44,707 --> 00:18:46,624 Unfortunately, your ulu did not make the cut. 543 00:18:46,709 --> 00:18:48,126 - Chad, you fought hard. 544 00:18:48,169 --> 00:18:49,544 This was a difficult challenge. 545 00:18:49,629 --> 00:18:51,295 But at the end of the day, 546 00:18:51,381 --> 00:18:54,298 the ergonomics of your handle will require the most work 547 00:18:54,384 --> 00:18:55,633 compared to the other blades, 548 00:18:55,677 --> 00:18:57,343 and that's the reason we're sending you home. 549 00:18:57,428 --> 00:18:58,928 - Thank you, sir. 550 00:18:59,013 --> 00:19:01,139 - Chad, man, you fought hard, all the way to the bitter end, 551 00:19:01,224 --> 00:19:02,640 but, unfortunately, the time has come. 552 00:19:02,725 --> 00:19:04,642 I'm gonna have to ask you to please surrender your work 553 00:19:04,686 --> 00:19:05,768 and leave the forge. 554 00:19:05,854 --> 00:19:07,145 ♪ ♪ 555 00:19:07,188 --> 00:19:08,729 - I have no regrets leaving here. 556 00:19:08,815 --> 00:19:10,648 I accomplished what I try to instill in my kids-- 557 00:19:10,733 --> 00:19:12,650 finishing what you started, not giving up, 558 00:19:12,694 --> 00:19:15,820 digging deep when you feel like you're physically exhausted. 559 00:19:15,905 --> 00:19:16,946 I feel like I put in the effort. 560 00:19:17,031 --> 00:19:18,614 I did my best. 561 00:19:18,700 --> 00:19:20,867 And I don't feel like I'm leaving here a loser today. 562 00:19:20,952 --> 00:19:24,120 ♪ ♪ 563 00:19:24,205 --> 00:19:25,496 - well, gentlemen, congratulations. 564 00:19:25,540 --> 00:19:27,456 The three of you have made it through round one, 565 00:19:27,542 --> 00:19:29,834 and you're going on to round two of our competition. 566 00:19:29,919 --> 00:19:31,377 In this round, you're gonna fix any issues 567 00:19:31,462 --> 00:19:33,796 that the judges brought up about your blades, 568 00:19:33,882 --> 00:19:35,047 as well as add handles to them, 569 00:19:35,133 --> 00:19:37,508 turning them into fully functioning ulus. 570 00:19:37,552 --> 00:19:39,135 Now, in this round, 571 00:19:39,179 --> 00:19:42,346 the only materials you are allowed to use for your handles 572 00:19:42,432 --> 00:19:45,850 have to be sourced from natural animal materials. 573 00:19:45,935 --> 00:19:47,852 That is antlers, that's bones, 574 00:19:47,896 --> 00:19:49,645 or that is hide or leather. 575 00:19:49,731 --> 00:19:50,771 ♪ ♪ 576 00:19:50,857 --> 00:19:51,981 now, after this round is complete, 577 00:19:52,066 --> 00:19:53,149 you'll turn your blades in. 578 00:19:53,234 --> 00:19:54,692 We'll check for strength and durability 579 00:19:54,777 --> 00:19:55,902 in a moose antler punch. 580 00:19:55,987 --> 00:19:57,320 Then we're gonna check the edge retention 581 00:19:57,405 --> 00:20:00,406 in an alaskan salmon slice. 582 00:20:00,491 --> 00:20:02,408 You have two hours on the clock. 583 00:20:02,493 --> 00:20:05,328 Good luck. Your time starts now. 584 00:20:05,413 --> 00:20:07,914 ♪ ♪ 585 00:20:07,999 --> 00:20:10,791 we've given them only natural animal materials 586 00:20:10,877 --> 00:20:12,293 for the handles. 587 00:20:12,378 --> 00:20:13,878 What options would you guys be going for? 588 00:20:13,922 --> 00:20:15,713 - If I had the choice, I'd be going with antler 589 00:20:15,798 --> 00:20:17,381 just 'cause it's durable 590 00:20:17,425 --> 00:20:19,342 and it puts up with a lot of stress. 591 00:20:19,427 --> 00:20:20,843 ♪ ♪ 592 00:20:20,887 --> 00:20:23,971 - the biggest thing on my mind at the start of round two 593 00:20:24,057 --> 00:20:25,681 is trying to fix my handle. 594 00:20:25,767 --> 00:20:28,684 I'm going to cut a piece of angle iron, 595 00:20:28,770 --> 00:20:29,685 form it to shape, 596 00:20:29,771 --> 00:20:32,146 and then weld it onto my tang. 597 00:20:32,232 --> 00:20:33,856 - Well, looks like clay is taking cladding 598 00:20:33,942 --> 00:20:35,983 on both sides of his handle, 599 00:20:36,069 --> 00:20:37,652 strengthening it up, beefing it up. 600 00:20:37,737 --> 00:20:39,362 - That's definitely a smart move. 601 00:20:39,447 --> 00:20:41,572 - I get all six pieces welded on. 602 00:20:41,658 --> 00:20:42,949 And then 603 00:20:43,034 --> 00:20:45,534 I know I have to tackle the cracks next. 604 00:20:45,620 --> 00:20:48,037 The cracks on my blade are right where my tang connects 605 00:20:48,081 --> 00:20:49,705 to my blade. 606 00:20:49,791 --> 00:20:51,415 That's a very crucial point. 607 00:20:51,459 --> 00:20:54,752 It is where all the stress from the punches is gonna go. 608 00:20:54,796 --> 00:20:56,754 What I'm gonna do is wrap my blade 609 00:20:56,798 --> 00:20:59,090 in a very wet towel, 610 00:20:59,133 --> 00:21:00,925 try to keep it as cool as I possibly can, 611 00:21:00,969 --> 00:21:04,595 and then just lightly weld the cracks. 612 00:21:04,639 --> 00:21:07,807 The last thing I need to happen is ruin my heat treat. 613 00:21:07,892 --> 00:21:09,600 I'm feeling pretty good about the cracks. 614 00:21:09,644 --> 00:21:11,269 I got a lot of stuff to do still. 615 00:21:11,312 --> 00:21:12,687 I don't think I have enough time to do it. 616 00:21:12,772 --> 00:21:13,896 I'm gonna be pushing. 617 00:21:13,982 --> 00:21:17,275 ♪ ♪ 618 00:21:17,360 --> 00:21:20,027 - what I'm doing to fix the cracks is welding them, 619 00:21:20,113 --> 00:21:22,071 trying to keep the blade as cool as possible, 620 00:21:22,156 --> 00:21:23,614 so as not to ruin the heat treat. 621 00:21:23,658 --> 00:21:25,116 [dramatic musical sting] 622 00:21:25,159 --> 00:21:27,201 that is a huge problem. 623 00:21:27,287 --> 00:21:28,661 - Oh. 624 00:21:28,746 --> 00:21:31,038 - Andrew's blade just cracked again. 625 00:21:31,124 --> 00:21:32,540 - Bad to worse. 626 00:21:32,625 --> 00:21:33,958 As I weld one crack shut, 627 00:21:34,043 --> 00:21:37,086 another crack forms on another part of the knif. 628 00:21:37,130 --> 00:21:38,546 - Why is his thing so brittle? 629 00:21:38,631 --> 00:21:41,924 - Probably because he worked it cold so much 630 00:21:42,010 --> 00:21:44,719 that it's not just the edges that have cracked, 631 00:21:44,804 --> 00:21:47,054 it's the entire structure. 632 00:21:47,140 --> 00:21:48,889 - In real life, you chuck that thing in a barrel, 633 00:21:48,975 --> 00:21:50,057 and you move on. 634 00:21:50,143 --> 00:21:51,976 Here, I don't have that luxury. 635 00:21:52,020 --> 00:21:54,603 I'm very hopeful that I have fixed the cracks 636 00:21:54,689 --> 00:21:56,105 that I have seen in the blad, 637 00:21:56,190 --> 00:21:58,441 but it's time to move on and get on to another problem. 638 00:21:58,526 --> 00:22:00,776 ♪ ♪ 639 00:22:00,862 --> 00:22:02,611 - dave mentioned that every time he squeezed down 640 00:22:02,697 --> 00:22:05,156 on my handle, it created some kind of a tension. 641 00:22:05,199 --> 00:22:06,574 I'm gonna widen it up a little bit 642 00:22:06,659 --> 00:22:08,743 so that grip can fit more comfortably. 643 00:22:08,828 --> 00:22:11,162 - The nice thing about devon's blade is that, 644 00:22:11,205 --> 00:22:13,664 you know, he's got already the blade in the shape we wanted, 645 00:22:13,750 --> 00:22:16,250 but getting the hand to be comfortable in there 646 00:22:16,336 --> 00:22:19,128 is very important in this particular design. 647 00:22:19,213 --> 00:22:21,339 - As I finish dremeling, I get it all widened up, 648 00:22:21,424 --> 00:22:22,965 it feels comfortable to me. 649 00:22:23,051 --> 00:22:24,759 And now I need to figure out what handle material 650 00:22:24,844 --> 00:22:25,843 that I could actually use. 651 00:22:25,887 --> 00:22:27,636 All right. That will do it. 652 00:22:27,722 --> 00:22:28,971 - All right, gentlemen, 653 00:22:29,057 --> 00:22:30,473 you guys are halfway through round two! 654 00:22:30,516 --> 00:22:32,016 There's 60 minutes remaining! 655 00:22:32,101 --> 00:22:33,851 - Hmm... 656 00:22:33,895 --> 00:22:36,479 How do I want to do this? 657 00:22:36,564 --> 00:22:38,773 My idea for my handle is, 658 00:22:38,858 --> 00:22:40,441 I'm going to use leather, 659 00:22:40,526 --> 00:22:43,652 and I'm gonna make a wrap that goes around my handle. 660 00:22:43,696 --> 00:22:47,198 - The issue I have with what he's doing is not the process. 661 00:22:47,283 --> 00:22:48,699 It's the material that he's using. 662 00:22:48,743 --> 00:22:50,159 Those pieces of leather he's got 663 00:22:50,203 --> 00:22:52,370 are only about 12 inches long, 664 00:22:52,455 --> 00:22:55,331 so you're only gonna get maybe two wraps up out of each. 665 00:22:55,375 --> 00:22:58,501 - What he's got, with small pieces in different sections, 666 00:22:58,544 --> 00:23:01,545 you have peaks and valleys that can create hotspots. 667 00:23:01,589 --> 00:23:03,381 - These strips are not very long. 668 00:23:03,424 --> 00:23:05,216 I don't have anything flat enough 669 00:23:05,259 --> 00:23:08,135 to put a scale of bone or antler on. 670 00:23:08,221 --> 00:23:11,013 So this is my only option, so I have to stick to it. 671 00:23:11,099 --> 00:23:13,224 Work with me here. 672 00:23:13,309 --> 00:23:15,601 - Bladesmiths, you have 30 minutes left! 673 00:23:15,686 --> 00:23:17,061 ♪ ♪ 674 00:23:17,146 --> 00:23:18,396 - I've got to get holes in the tang 675 00:23:18,481 --> 00:23:19,939 so that I can get a handle on this thing. 676 00:23:20,024 --> 00:23:21,649 [high-pitched whirring] 677 00:23:21,734 --> 00:23:23,359 - ooh. 678 00:23:23,444 --> 00:23:25,528 - Aw, man. What the hell? 679 00:23:25,571 --> 00:23:26,904 I got nothing. 680 00:23:26,989 --> 00:23:29,073 - If that bit isn't going through that steel yet, 681 00:23:29,158 --> 00:23:30,866 it's not going through at all. 682 00:23:30,910 --> 00:23:33,369 - When I quenched my blade, it had flamed up so badly 683 00:23:33,454 --> 00:23:36,163 that I went ahead and quenched the entire knif. 684 00:23:36,249 --> 00:23:38,624 A hard knife is impossible to drill through. 685 00:23:38,709 --> 00:23:40,084 Come on. 686 00:23:40,169 --> 00:23:42,420 I realize that I need to soften it enouh 687 00:23:42,463 --> 00:23:44,255 to get a hole in it. 688 00:23:44,298 --> 00:23:47,091 I heat the tang of the knife up to a really dark blue, 689 00:23:47,176 --> 00:23:49,885 which I think ought to be soft enough. 690 00:23:49,971 --> 00:23:51,846 What do you know? 691 00:23:51,931 --> 00:23:53,514 - There you go. 692 00:23:53,599 --> 00:23:55,141 - Between fixing the cracks, 693 00:23:55,226 --> 00:23:57,726 trying to get a hole through my tang, I'm almost out of time. 694 00:23:57,770 --> 00:24:01,021 I've got to get the scales and the leather that I chose 695 00:24:01,107 --> 00:24:02,273 on the tang 696 00:24:02,358 --> 00:24:04,024 and get the pin through the hole 697 00:24:04,110 --> 00:24:06,569 so that I've had met that parameter at least. 698 00:24:06,654 --> 00:24:09,613 ♪ ♪ 699 00:24:09,657 --> 00:24:11,657 - I have only, like, two experiences 700 00:24:11,742 --> 00:24:12,867 making natural handles. 701 00:24:12,952 --> 00:24:14,076 I've used bone before. 702 00:24:14,162 --> 00:24:15,453 The problem is, bone is so brittle, 703 00:24:15,538 --> 00:24:17,538 and it's mostly hollow, too, 704 00:24:17,623 --> 00:24:19,665 you don't know the integrity of that handle material. 705 00:24:19,750 --> 00:24:22,543 So I'm gonna be using buffalo horn. 706 00:24:22,628 --> 00:24:24,044 Come on. 707 00:24:24,130 --> 00:24:25,713 My plan for the rest of this round is to make sure 708 00:24:25,798 --> 00:24:27,756 this handle fits comfortably on my ulu 709 00:24:27,842 --> 00:24:30,134 and the edge is as sharp as I can possibly get it. 710 00:24:30,219 --> 00:24:32,470 - Doug, what do you think about edge geometry on the ulu? 711 00:24:32,555 --> 00:24:34,430 - Despite the fact that you have a handle 712 00:24:34,515 --> 00:24:36,640 that looks like it's forward and for punching, 713 00:24:36,684 --> 00:24:40,186 you're still slicing with the curvature of that material, 714 00:24:40,271 --> 00:24:42,438 same thing as you would skin or working. 715 00:24:42,523 --> 00:24:44,315 ♪ ♪ 716 00:24:44,358 --> 00:24:47,902 - after I got my epoxy set on the handle, 717 00:24:47,987 --> 00:24:50,571 I'm realizing that this is taking a lot more time 718 00:24:50,656 --> 00:24:52,656 than I have available, 719 00:24:52,700 --> 00:24:54,450 and now I need to get right to the grinder 720 00:24:54,535 --> 00:24:56,160 and start shaping my blade. 721 00:24:56,245 --> 00:24:57,578 [bleep]. 722 00:24:57,663 --> 00:24:58,996 - Oh. 723 00:24:59,040 --> 00:25:01,415 - The weld that was covering up this crack, 724 00:25:01,501 --> 00:25:02,833 it re-exposed itself. 725 00:25:02,877 --> 00:25:04,376 [bleep] kidding me. 726 00:25:04,462 --> 00:25:06,504 If I don't fix this blade right now, 727 00:25:06,547 --> 00:25:08,297 it could break in testing. 728 00:25:08,341 --> 00:25:09,548 Then I'm done. 729 00:25:09,634 --> 00:25:14,678 ♪ ♪ 730 00:25:14,764 --> 00:25:16,263 - this could send me home. 731 00:25:16,349 --> 00:25:16,931 I know the only way I can fix it at this point is 732 00:25:17,016 --> 00:25:18,224 weld it shut. 733 00:25:18,309 --> 00:25:19,850 [dramatic music] 734 00:25:19,894 --> 00:25:22,436 all I can do is hope that it's gonna hold strong enough. 735 00:25:22,522 --> 00:25:23,854 ♪ ♪ 736 00:25:23,898 --> 00:25:26,649 - gentlemen, you have three minutes remaining! 737 00:25:26,734 --> 00:25:29,860 - All I want to do is get a handle on this tang. 738 00:25:29,946 --> 00:25:31,612 I want to get the pin in the hole. 739 00:25:31,697 --> 00:25:34,198 - He's trying to drill his handle scales right now. 740 00:25:34,242 --> 00:25:37,034 - Get it going. - Down to the wire. 741 00:25:37,078 --> 00:25:38,494 - The clock is really ticking down. 742 00:25:38,579 --> 00:25:40,037 We've got minutes left. 743 00:25:40,081 --> 00:25:42,206 - If andrew can pull this off, I'm gonna be impressed. 744 00:25:42,291 --> 00:25:44,208 - I get back to my table just in time 745 00:25:44,252 --> 00:25:46,377 to get the pin stock cut off 746 00:25:46,420 --> 00:25:48,879 and put a couple of clamps on the scales. 747 00:25:48,923 --> 00:25:50,130 I really hope it's good enough. 748 00:25:50,216 --> 00:25:51,966 ♪ ♪ 749 00:25:52,051 --> 00:25:53,634 - five, four, 750 00:25:53,719 --> 00:25:56,387 three, two, one. 751 00:25:56,430 --> 00:25:59,014 Gentlemen, turn off your machines, put down your tools. 752 00:25:59,058 --> 00:26:01,058 Round two is officially over. 753 00:26:01,102 --> 00:26:04,562 ♪ ♪ 754 00:26:04,605 --> 00:26:07,231 - I have some real issues with my knife, 755 00:26:07,275 --> 00:26:09,358 but it's always possible that somebody else 756 00:26:09,443 --> 00:26:11,569 is going to have bigger issues than I do, 757 00:26:11,654 --> 00:26:13,737 so it's really all up to chance at this point. 758 00:26:13,781 --> 00:26:15,447 ♪ ♪ 759 00:26:15,533 --> 00:26:18,242 - all right, gentlemen, it's time for the strength test. 760 00:26:18,327 --> 00:26:20,077 And to keep with our arctic theme, 761 00:26:20,121 --> 00:26:23,455 we're going with the moose antler punch and chop. 762 00:26:23,541 --> 00:26:24,707 Remember, this is not 763 00:26:24,792 --> 00:26:26,792 about what your ulu does to the antler, 764 00:26:26,877 --> 00:26:28,210 but what that antler can do to your ulu. 765 00:26:28,296 --> 00:26:29,753 Clay, you're up first. Are you ready? 766 00:26:29,797 --> 00:26:32,256 - I guess so. - Well, I'm gonna do it anyway. 767 00:26:32,341 --> 00:26:34,300 - Dave's punched me before. It's not that bad. 768 00:26:34,385 --> 00:26:35,884 - [chuckles] 769 00:26:35,928 --> 00:26:37,428 - want me to punch you again? 770 00:26:37,513 --> 00:26:39,263 [laughter] 771 00:26:39,307 --> 00:26:40,764 - I addressed the cracks, 772 00:26:40,808 --> 00:26:42,725 filled them with weld, ground them down, 773 00:26:42,810 --> 00:26:45,769 but they're about to punch my blade into a moose antler. 774 00:26:45,855 --> 00:26:48,105 That's one of the toughest objects out there. 775 00:26:48,190 --> 00:26:50,774 And I don't know if I'll be able to watch when it happens. 776 00:26:50,818 --> 00:26:54,111 ♪ ♪ 777 00:26:54,155 --> 00:26:57,156 - [grunting] 778 00:26:57,241 --> 00:27:00,200 [rock music] 779 00:27:00,286 --> 00:27:04,121 ♪ ♪ 780 00:27:04,165 --> 00:27:05,998 - holy sh... 781 00:27:06,083 --> 00:27:07,875 Bleep. 782 00:27:07,960 --> 00:27:09,293 - I take it back. 783 00:27:09,337 --> 00:27:10,836 [scattered laughter] 784 00:27:10,921 --> 00:27:13,964 [dramatic music] 785 00:27:14,008 --> 00:27:16,091 - all right, clay, let's talk about your ulu. 786 00:27:16,177 --> 00:27:18,594 Now, right off, it's got a good cutting edge, 787 00:27:18,679 --> 00:27:20,971 and it didn't lose any of that edge, so that's good. 788 00:27:21,057 --> 00:27:22,806 As far as the handle goes, 789 00:27:22,892 --> 00:27:24,475 it's a rough construction. 790 00:27:24,518 --> 00:27:25,643 Without a glove on, 791 00:27:25,728 --> 00:27:27,144 this is really not a comfortable handle. 792 00:27:27,229 --> 00:27:28,771 There are, 793 00:27:28,856 --> 00:27:31,315 you know, parts that are kind of sticking up. 794 00:27:31,359 --> 00:27:32,983 But it didn't hurt my hand. 795 00:27:33,027 --> 00:27:34,318 Stayed where I wanted it to be. 796 00:27:34,362 --> 00:27:36,153 So good job. - Thank you. 797 00:27:36,238 --> 00:27:38,489 - All right, andrew, you're up. Are you ready? 798 00:27:38,532 --> 00:27:40,574 - Knock it out. - Okay. 799 00:27:40,660 --> 00:27:42,201 ♪ ♪ 800 00:27:42,286 --> 00:27:45,329 - the idea of smashing the edge of that knife 801 00:27:45,373 --> 00:27:47,665 into a moose antler terrifies me. 802 00:27:47,750 --> 00:27:49,583 I don't know what's going to happen. 803 00:27:49,669 --> 00:27:51,585 It's really all up to chance at this point. 804 00:27:51,671 --> 00:28:02,304 ♪ ♪ 805 00:28:02,390 --> 00:28:03,597 ♪ ♪ 806 00:28:03,683 --> 00:28:04,848 [knife clatters] 807 00:28:04,892 --> 00:28:08,310 ♪ ♪ 808 00:28:08,396 --> 00:28:09,520 - so, andrew-- - yeah. 809 00:28:09,605 --> 00:28:11,647 - There are some obvious issues with this. 810 00:28:11,691 --> 00:28:13,482 When you were drilling to mount the handle, 811 00:28:13,567 --> 00:28:15,317 there was some overworking 812 00:28:15,403 --> 00:28:17,361 and not good thermal cycling going on 813 00:28:17,446 --> 00:28:18,737 to reduce that grain structure 814 00:28:18,823 --> 00:28:20,906 and give it the strength that it needs. 815 00:28:20,991 --> 00:28:23,534 Once I hit this face-on, it just cut loose. 816 00:28:23,577 --> 00:28:24,993 ♪ ♪ 817 00:28:25,079 --> 00:28:26,370 - you good? - Yeah. 818 00:28:26,414 --> 00:28:28,706 - Yeah? - Yeah. 819 00:28:28,749 --> 00:28:30,833 - Well, andrew, that is an absolutely tough break. 820 00:28:30,918 --> 00:28:32,876 Unfortunately, you had a catastrophic failure 821 00:28:32,962 --> 00:28:36,088 in your blade, which means we cannot test your ulu furthe. 822 00:28:36,173 --> 00:28:37,756 Clay, congratulations. 823 00:28:37,842 --> 00:28:39,007 That means you're moving forward 824 00:28:39,051 --> 00:28:41,552 into round three of this competition. 825 00:28:41,595 --> 00:28:44,179 Devon, not quite out of the woods yet. 826 00:28:44,265 --> 00:28:46,181 You got to make it through a solid punch. 827 00:28:46,267 --> 00:28:47,850 Ready? - Yeah, let's get weird. 828 00:28:47,935 --> 00:28:49,268 - All right, let's do it. Dave. 829 00:28:49,353 --> 00:28:51,270 - [chuckles] "get weird." 830 00:28:51,355 --> 00:28:53,772 - careful what you ask for. 831 00:28:53,858 --> 00:28:55,733 - I'm actually really confident in my blade. 832 00:28:55,818 --> 00:28:57,526 I specifically styled my ulu 833 00:28:57,611 --> 00:28:59,236 for these kind of tests coming up. 834 00:28:59,321 --> 00:29:01,113 But anything can happen with the strength test. 835 00:29:01,198 --> 00:29:04,658 [rock music] 836 00:29:04,744 --> 00:29:11,540 ♪ ♪ 837 00:29:11,625 --> 00:29:15,085 - so, devon, your design is pretty much spot-on for an ulu. 838 00:29:15,171 --> 00:29:17,337 As far as holding up in this test, 839 00:29:17,423 --> 00:29:20,591 you really didn't take in any damage at all. 840 00:29:20,676 --> 00:29:23,093 I feel like I can work with this either skinning 841 00:29:23,137 --> 00:29:24,887 or chopping. 842 00:29:24,930 --> 00:29:26,263 And the blade held up beautifully. 843 00:29:26,307 --> 00:29:27,598 Nicely done. - Thank you. 844 00:29:27,641 --> 00:29:30,100 ♪ ♪ 845 00:29:30,144 --> 00:29:31,935 - well, gentlemen, you guys all did a great job, 846 00:29:31,979 --> 00:29:35,397 but, andrew, unfortunately, we can't continue testing. 847 00:29:35,483 --> 00:29:37,107 Your time here in the forge has ended, man. 848 00:29:37,151 --> 00:29:39,401 I'm gonna have to ask you to please step out. 849 00:29:39,487 --> 00:29:41,945 - Let the young dogs play. 850 00:29:41,989 --> 00:29:44,239 It wasn't a big shock for me when the blade failed. 851 00:29:44,325 --> 00:29:45,991 There were a lot of things wrong with that blade, 852 00:29:46,076 --> 00:29:48,035 and it would have taken a miracle 853 00:29:48,120 --> 00:29:49,870 for me to be able to get through to the finale. 854 00:29:49,955 --> 00:29:51,789 My wife's been bugging me to make her an ulu, 855 00:29:51,832 --> 00:29:53,791 so when I get home, one of the first things that I'll do 856 00:29:53,834 --> 00:29:56,293 is make a decent ulu that will be useful in the kitchen. 857 00:29:56,337 --> 00:29:57,795 And it's not gonna be used to punch antlers 858 00:29:57,838 --> 00:29:59,546 or do crazy stuff like that. 859 00:29:59,632 --> 00:30:02,132 ♪ ♪ 860 00:30:02,218 --> 00:30:03,717 - well, gentlemen, congratulations 861 00:30:03,803 --> 00:30:05,135 to the two of you. 862 00:30:05,179 --> 00:30:06,637 You have beat out the competition in the first 863 00:30:06,680 --> 00:30:08,847 and second round of our arctic forge challenge, 864 00:30:08,933 --> 00:30:10,516 which means you're both one step closer 865 00:30:10,601 --> 00:30:12,267 to a check for $10,000 866 00:30:12,353 --> 00:30:13,977 and the title of "forged in fire" champion. 867 00:30:14,063 --> 00:30:15,813 Now, guys, in this final round of competition, 868 00:30:15,856 --> 00:30:17,940 we're gonna be sending you back to your home forges 869 00:30:18,025 --> 00:30:21,777 to build yet another iconic weapon from the ice-cold north. 870 00:30:21,862 --> 00:30:22,903 That weapon is... 871 00:30:22,988 --> 00:30:24,696 ♪ ♪ 872 00:30:24,782 --> 00:30:26,907 the northern long seax. 873 00:30:26,992 --> 00:30:28,784 ♪ ♪ 874 00:30:28,869 --> 00:30:30,828 - the northern long seax is a single-edge blade 875 00:30:30,871 --> 00:30:33,956 widely used by vikings and northern european tribes 876 00:30:34,041 --> 00:30:35,999 during the middle ages. 877 00:30:36,085 --> 00:30:38,126 Its razor-sharp edge and pointed tip 878 00:30:38,212 --> 00:30:40,838 were useful in slashing, as well as for thrusting, 879 00:30:40,881 --> 00:30:43,799 allowing the user to deliver heavy blows and stabs 880 00:30:43,884 --> 00:30:46,844 to finish off an opponent in close-quarter combat. 881 00:30:46,929 --> 00:30:48,595 Although used as a deadly weapon, 882 00:30:48,681 --> 00:30:51,056 the vikings would also use the seax to hack tree branchs 883 00:30:51,141 --> 00:30:53,433 and skin animals. 884 00:30:53,519 --> 00:30:55,269 Today the versatile blade can be seen 885 00:30:55,354 --> 00:30:58,272 in netflix's historical drama series "the last kingdom" 886 00:30:58,357 --> 00:30:59,690 ♪ ♪ 887 00:30:59,775 --> 00:31:01,650 - now, gentlemen, when you're building your seaxes, 888 00:31:01,735 --> 00:31:03,235 I want you to follow these parameters. 889 00:31:03,320 --> 00:31:04,695 The blade length needs to measure 890 00:31:04,738 --> 00:31:07,281 between 21 and 23 inches in a straight line, 891 00:31:07,366 --> 00:31:09,199 from tip to the base of the blade. 892 00:31:09,243 --> 00:31:10,659 And we want you to make these blades 893 00:31:10,744 --> 00:31:12,870 with a layered damascus pattern. 894 00:31:12,955 --> 00:31:15,205 - I've never made anything 895 00:31:15,249 --> 00:31:17,207 close to this size before. 896 00:31:17,251 --> 00:31:19,543 What am I gonna do? How am I gonna do this? 897 00:31:19,587 --> 00:31:20,919 ♪ ♪ 898 00:31:21,005 --> 00:31:22,254 - now, guys, you will only have four days 899 00:31:22,339 --> 00:31:23,505 to build these blades. 900 00:31:23,591 --> 00:31:25,549 When you come back, we want to see two seaxes 901 00:31:25,634 --> 00:31:27,885 that are worth at least $10,000 apiece 902 00:31:27,928 --> 00:31:29,803 because that's what one of them will win you. 903 00:31:29,889 --> 00:31:31,972 Good luck, guys. We'll see you in four days. 904 00:31:32,057 --> 00:31:33,807 - Good luck. - Yeah. 905 00:31:33,893 --> 00:31:36,727 ♪ ♪ 906 00:31:36,770 --> 00:31:38,270 today I'm working on a northern long seax. 907 00:31:38,355 --> 00:31:39,688 I'm really excited to get this going. 908 00:31:39,773 --> 00:31:41,356 Get this thing cooking! 909 00:31:41,442 --> 00:31:42,566 What I'm gonna do today 910 00:31:42,651 --> 00:31:44,234 is I'm gonna start this damascus billet, 911 00:31:44,278 --> 00:31:45,861 get everything forge welded and drawn out. 912 00:31:45,946 --> 00:31:47,613 And I actually plan on getting the blade completed today. 913 00:31:47,698 --> 00:31:49,031 Oh, my gosh. 914 00:31:49,116 --> 00:31:52,159 I notice that it concaved going up to the drop point, 915 00:31:52,244 --> 00:31:54,411 so I'm going to just start drawing out that metal, 916 00:31:54,496 --> 00:31:55,829 wide as possible, 917 00:31:55,915 --> 00:31:57,372 because I need this to make parameters. 918 00:31:57,416 --> 00:31:59,875 There we go. That's what I was looking for. 919 00:31:59,919 --> 00:32:01,543 Well, I'm not gonna lie. 920 00:32:01,629 --> 00:32:03,587 That was more of a challenge than I thought it was gonna be, 921 00:32:03,631 --> 00:32:06,340 but by the end of it, I couldn't be more proud. 922 00:32:06,425 --> 00:32:08,175 ♪ ♪ 923 00:32:08,260 --> 00:32:10,427 I think that will be it for today, though. 924 00:32:10,471 --> 00:32:13,305 ♪ ♪ 925 00:32:13,390 --> 00:32:14,848 - I just got back to my home forge, 926 00:32:14,934 --> 00:32:17,476 and I'm about to start working on my northern long seax. 927 00:32:17,561 --> 00:32:20,312 Now I'm gonna start cutting my damascus billets out. 928 00:32:20,397 --> 00:32:22,272 I've never made 929 00:32:22,316 --> 00:32:25,150 a damascus knife of such length before, 930 00:32:25,235 --> 00:32:27,444 so that's gonna be a very big challenge-- 931 00:32:27,488 --> 00:32:30,739 trying to get something drawn out and stay together. 932 00:32:30,824 --> 00:32:32,824 Those look like they're setting really well. 933 00:32:32,910 --> 00:32:34,952 If I could wrap up today in two words, 934 00:32:34,995 --> 00:32:36,328 it would be "surprisingly smooth." 935 00:32:36,413 --> 00:32:37,788 I'm so far ahead 936 00:32:37,831 --> 00:32:39,790 of where I wanted to be at the end of today, 937 00:32:39,875 --> 00:32:41,625 might be able to take it a little easy tomorrow. 938 00:32:41,669 --> 00:32:43,710 ♪ ♪ 939 00:32:43,796 --> 00:32:45,796 - day two. I'm feeling excited. 940 00:32:45,881 --> 00:32:47,297 Let's get started on the handle. 941 00:32:47,383 --> 00:32:49,925 I'm going to cut up some aluminum bar stock 942 00:32:50,010 --> 00:32:51,093 for the pommel. 943 00:32:51,178 --> 00:32:53,637 It threads. Whee-hoo! 944 00:32:53,681 --> 00:32:55,973 ♪ ♪ 945 00:32:56,016 --> 00:32:58,809 it's off slightly. Noticeably slightly. 946 00:32:58,852 --> 00:33:01,520 Well, there's a catastrophe for ya! 947 00:33:01,605 --> 00:33:03,146 The pommel fit snug, 948 00:33:03,232 --> 00:33:04,815 but it was uneven with the actual blade. 949 00:33:04,900 --> 00:33:07,484 I want to make sure it's as even as possible 950 00:33:07,569 --> 00:33:09,695 without taking any more material away from it. 951 00:33:09,780 --> 00:33:12,114 I have to start all over with the pommel. 952 00:33:12,199 --> 00:33:15,117 What I need to do is re-center it, re-hole, and then also 953 00:33:15,202 --> 00:33:17,828 make sure it sets up perfectly and beautifully. 954 00:33:17,913 --> 00:33:19,496 All right. 955 00:33:19,581 --> 00:33:22,165 You know what? Glad it happened. 956 00:33:22,251 --> 00:33:23,291 Now it's even more snug. 957 00:33:23,377 --> 00:33:24,751 ♪ ♪ 958 00:33:24,837 --> 00:33:27,212 - so today I'm going to finish grinding 959 00:33:27,297 --> 00:33:29,172 on my blade, get a nice finished shape. 960 00:33:29,216 --> 00:33:30,716 There we go. 961 00:33:30,801 --> 00:33:33,385 So I decide to put some detail on my spine, 962 00:33:33,470 --> 00:33:35,262 make it stand out a little bit, 963 00:33:35,347 --> 00:33:39,307 and as I'm looking at it, my handle has a twist to it. 964 00:33:39,393 --> 00:33:42,019 If my handle has a twist, then it's not gonna swing right, 965 00:33:42,062 --> 00:33:44,229 it's not gonna fit right, it's not gonna cut right. 966 00:33:44,314 --> 00:33:46,314 Cannot turn something in like that. 967 00:33:46,400 --> 00:33:53,447 I could be looking at a $10,000 mistake. 968 00:33:53,532 --> 00:33:54,823 I'm going to stick it in the forge 969 00:33:54,908 --> 00:33:55,741 and try to hammer this straight. 970 00:33:55,826 --> 00:33:57,284 There's a slight warp, 971 00:33:57,369 --> 00:33:59,202 but that'll have to do. 972 00:33:59,288 --> 00:34:00,996 Well, I got the forge lit, 973 00:34:01,081 --> 00:34:04,916 so we might as well try to heat-treat this thing. 974 00:34:05,002 --> 00:34:08,003 [dramatic music] 975 00:34:08,088 --> 00:34:09,921 ♪ ♪ 976 00:34:10,007 --> 00:34:11,173 hard. 977 00:34:11,258 --> 00:34:12,758 Good quench. Good quench. 978 00:34:12,843 --> 00:34:14,676 - Day four. 979 00:34:14,762 --> 00:34:17,679 Yesterday I got a lot farther than I thought with my weapon, 980 00:34:17,765 --> 00:34:19,514 and I'm actually very pleased with it, 981 00:34:19,600 --> 00:34:21,600 so today I'm just gonna focus on the little details. 982 00:34:21,685 --> 00:34:23,685 I know my handle's a bit plain and bland, 983 00:34:23,771 --> 00:34:25,228 but at least it'll be shiny. 984 00:34:25,272 --> 00:34:27,064 I'm a little worried that I'm almost done. 985 00:34:27,149 --> 00:34:29,274 I hope I didn't skip over anything. 986 00:34:29,359 --> 00:34:31,193 I just want to make sure this weapon will perform. 987 00:34:31,278 --> 00:34:33,320 So at the end of this day, I will be testing it out 988 00:34:33,405 --> 00:34:34,905 as much as I can. 989 00:34:34,990 --> 00:34:37,908 [exhales deeply] okay, here we go. 990 00:34:37,951 --> 00:34:41,578 [laughing] 991 00:34:41,663 --> 00:34:43,455 sliced right through. 992 00:34:43,540 --> 00:34:46,083 I got my blade done. I'm very happy with it. 993 00:34:46,126 --> 00:34:47,626 It cuts, it keals. 994 00:34:47,711 --> 00:34:49,878 It's pretty much perfect. 995 00:34:49,963 --> 00:34:52,422 ♪ ♪ 996 00:34:52,466 --> 00:34:53,840 - I'm way ahead of where I expected to be 997 00:34:53,926 --> 00:34:55,050 going into day four. 998 00:34:55,094 --> 00:34:56,927 Today I can refine my handle 999 00:34:56,970 --> 00:34:59,221 and probably test my sharpness. 1000 00:34:59,306 --> 00:35:01,056 This wood I'm using is walnut, 1001 00:35:01,141 --> 00:35:03,225 and what's special about this is 1002 00:35:03,310 --> 00:35:05,102 this tree grew on my family farm 1003 00:35:05,187 --> 00:35:08,271 and was cut down in our family sawmill. 1004 00:35:08,315 --> 00:35:09,898 It looks amazing. 1005 00:35:09,942 --> 00:35:11,191 I couldn't be happier. 1006 00:35:11,276 --> 00:35:12,609 I have an edge on this, 1007 00:35:12,653 --> 00:35:15,070 but I really want to see how sharp it is, 1008 00:35:15,114 --> 00:35:16,655 so I need to test this blade. 1009 00:35:16,740 --> 00:35:18,365 I really hope that this is gonna 1010 00:35:18,450 --> 00:35:20,283 cut through these bottles with ease. 1011 00:35:20,369 --> 00:35:23,912 I hope my blade's sharp enough, but we're gonna find out. 1012 00:35:23,997 --> 00:35:25,539 ♪ ♪ 1013 00:35:25,624 --> 00:35:26,915 this blade just cut 1014 00:35:27,000 --> 00:35:28,583 right through the water bottles with ease. 1015 00:35:28,627 --> 00:35:29,918 They're clean cuts. 1016 00:35:29,962 --> 00:35:31,461 I couldn't be happier. 1017 00:35:31,505 --> 00:35:33,588 I feel confident sending this back to the forge. 1018 00:35:33,674 --> 00:35:35,757 I can't wait to see it tested. 1019 00:35:35,843 --> 00:35:40,428 ♪ ♪ 1020 00:35:40,514 --> 00:35:41,888 - gentlemen, welcome back to the forge. 1021 00:35:41,974 --> 00:35:43,056 Guys, great to have you here. 1022 00:35:43,142 --> 00:35:44,766 We sent you back to your home forges 1023 00:35:44,852 --> 00:35:47,561 to work on your northern long seaxes for four days. 1024 00:35:47,646 --> 00:35:49,604 They both look great, 1025 00:35:49,690 --> 00:35:51,606 but in this forge, there's only one champion, 1026 00:35:51,692 --> 00:35:53,150 which means only one of those blades 1027 00:35:53,193 --> 00:35:54,734 is gonna end up on our wall. 1028 00:35:54,820 --> 00:35:56,820 Before we get into the testing, I want to hear about them. 1029 00:35:56,864 --> 00:35:58,113 So, clay, how did it go for you? 1030 00:35:58,198 --> 00:36:00,115 ♪ ♪ 1031 00:36:00,200 --> 00:36:02,409 - my blade is a low-layer damascus 1032 00:36:02,494 --> 00:36:04,953 with 1095 and 15n20, 1033 00:36:05,038 --> 00:36:07,080 an integral pommel, and my handle is walnut 1034 00:36:07,166 --> 00:36:08,832 that was grown on my family farm 1035 00:36:08,917 --> 00:36:12,127 and cut on my dad's sawmill, so it's kind of special to me. 1036 00:36:12,212 --> 00:36:13,795 - Great. Devon, how about you? 1037 00:36:13,881 --> 00:36:15,714 ♪ ♪ 1038 00:36:15,799 --> 00:36:17,549 - mine's also a low-layer damascus. 1039 00:36:17,634 --> 00:36:19,217 1520, 1095. 1040 00:36:19,303 --> 00:36:21,136 The handle I chose was african blackwood. 1041 00:36:21,180 --> 00:36:23,263 I'm looking forward to this. 1042 00:36:23,348 --> 00:36:25,015 - Well, gentlemen, they both look fantastic, 1043 00:36:25,100 --> 00:36:26,391 and they both look deadly, 1044 00:36:26,476 --> 00:36:27,976 but there's only one way for us to find out 1045 00:36:28,061 --> 00:36:30,604 which one of these blades is gonna end up above the rest. 1046 00:36:30,689 --> 00:36:32,856 We've got a strength test. We've got a sharpness tes. 1047 00:36:32,900 --> 00:36:34,608 And up first, I'm gonna hand you to doug marcaida 1048 00:36:34,693 --> 00:36:35,984 for the keal. 1049 00:36:36,069 --> 00:36:37,694 ♪ ♪ 1050 00:36:37,779 --> 00:36:41,781 - all right, bladesmiths, welcome to the keal test. 1051 00:36:41,867 --> 00:36:44,534 To find out what kind of lethal damage your weapons will do, 1052 00:36:44,620 --> 00:36:46,828 I will take your weapon and deliver some lethal blows 1053 00:36:46,914 --> 00:36:48,788 on this pig carcass. 1054 00:36:48,874 --> 00:36:50,373 Clay, you ready to play? 1055 00:36:50,459 --> 00:36:51,666 - Yes, sir. - All right, let's do this. 1056 00:36:51,752 --> 00:36:53,376 ♪ ♪ 1057 00:36:53,462 --> 00:36:55,754 - I've never used my blade on anything like this before, 1058 00:36:55,839 --> 00:36:58,381 and my heart's just thumping in my chest. 1059 00:36:58,425 --> 00:37:01,176 I just really want to turn this pig into some pork chops. 1060 00:37:01,261 --> 00:37:08,225 ♪ ♪ 1061 00:37:18,028 --> 00:37:19,736 - oh. 1062 00:37:19,821 --> 00:37:21,238 - All right, clay, let's talk 1063 00:37:21,323 --> 00:37:23,531 about your northern long seax here. 1064 00:37:23,617 --> 00:37:26,409 You have a forward-heavy blade. 1065 00:37:26,453 --> 00:37:28,245 With that forward weight, 1066 00:37:28,330 --> 00:37:31,373 it really allows for deeper chops. 1067 00:37:31,458 --> 00:37:32,999 The edges are sharp. 1068 00:37:33,085 --> 00:37:34,751 They cut deep. 1069 00:37:34,795 --> 00:37:38,004 And overall, sir, your weapon... 1070 00:37:38,090 --> 00:37:39,172 It will keal. 1071 00:37:39,258 --> 00:37:40,590 - That's all I wanted to hear. 1072 00:37:40,676 --> 00:37:42,884 - All right, dapper devon. - [chuckles] 1073 00:37:42,970 --> 00:37:44,261 - you're up next. Are you ready, sir? 1074 00:37:44,304 --> 00:37:46,179 - I'm pumped. Let's do this. 1075 00:37:46,265 --> 00:37:49,015 Hitting the spine of this pig could fracture my blade, 1076 00:37:49,101 --> 00:37:50,433 chip it, warp it. 1077 00:37:50,519 --> 00:37:53,895 My stomach has never been so far up my throat before. 1078 00:37:53,981 --> 00:37:58,692 ♪ ♪ 1079 00:38:03,532 --> 00:38:05,907 and I am just hoping that this goes well. 1080 00:38:05,993 --> 00:38:09,619 ♪ ♪ 1081 00:38:09,705 --> 00:38:12,747 - [grunting] 1082 00:38:12,833 --> 00:38:19,754 ♪ ♪ 1083 00:38:21,008 --> 00:38:23,008 - [exhales sharply] 1084 00:38:23,093 --> 00:38:26,511 ♪ ♪ 1085 00:38:26,596 --> 00:38:28,513 - nice. 1086 00:38:28,598 --> 00:38:30,598 - Thanks, man. 1087 00:38:30,684 --> 00:38:33,476 - All right, devon, let's talk about your weapon here. 1088 00:38:33,520 --> 00:38:35,979 The blade you have here is nicely balanced, 1089 00:38:36,064 --> 00:38:39,607 that, when I cut, the weapon does not do the work for me. 1090 00:38:39,693 --> 00:38:42,110 I do the work with every slash. 1091 00:38:42,195 --> 00:38:45,864 As you can see, I cut it down twice all the way through. 1092 00:38:45,949 --> 00:38:49,492 Overall, sir, your northern long seax... 1093 00:38:49,578 --> 00:38:50,577 It'll keal. 1094 00:38:50,662 --> 00:38:52,537 - Thank you, sir. 1095 00:38:52,622 --> 00:38:55,999 ♪ ♪ 1096 00:38:56,043 --> 00:38:58,460 - bladesmiths, welcome to our strength test. 1097 00:38:58,545 --> 00:39:00,295 Fittingly, for this arctic challenge, 1098 00:39:00,339 --> 00:39:02,297 we're gonna do the ice block chop. 1099 00:39:02,382 --> 00:39:03,590 ♪ ♪ 1100 00:39:03,675 --> 00:39:05,133 it really tests the edge holding 1101 00:39:05,218 --> 00:39:07,135 and overall construction of your knives. 1102 00:39:07,220 --> 00:39:08,553 And it's a lot of fun, too. 1103 00:39:08,638 --> 00:39:09,846 ♪ ♪ 1104 00:39:09,890 --> 00:39:11,389 clay, you're up first. You ready to go? 1105 00:39:11,475 --> 00:39:13,141 - Give her hell. - I could do that. 1106 00:39:13,226 --> 00:39:14,726 [laughter] 1107 00:39:14,811 --> 00:39:16,144 - I saw a block of ice. 1108 00:39:16,229 --> 00:39:17,937 I know that's a super-tough test. 1109 00:39:18,023 --> 00:39:19,856 This whole competition started with an ice block, 1110 00:39:19,941 --> 00:39:22,692 and I really hope it doesn't end because of an ice block. 1111 00:39:22,736 --> 00:39:25,653 - [grunting] 1112 00:39:25,739 --> 00:39:30,867 ♪ ♪ 1113 00:39:30,952 --> 00:39:33,995 [knife clattering] 1114 00:39:34,081 --> 00:39:37,999 ♪ ♪ 1115 00:39:38,085 --> 00:39:40,418 - [exhales deeply] - [groans] 1116 00:39:40,504 --> 00:39:42,670 ♪ ♪ 1117 00:39:42,756 --> 00:39:44,547 all right, clay, you got a little bit of an issue here. 1118 00:39:44,633 --> 00:39:47,550 Your grain's not that bad. 1119 00:39:47,636 --> 00:39:50,303 I mean, it could be finer, but it's not that bad. 1120 00:39:50,389 --> 00:39:52,806 But every time I hit, 1121 00:39:52,891 --> 00:39:55,308 that blade just vibrated like crazy, 1122 00:39:55,394 --> 00:39:56,976 and it just traveled down. 1123 00:39:57,062 --> 00:39:58,561 So it started to bend, 1124 00:39:58,605 --> 00:40:00,105 and then all that vibration and everything, 1125 00:40:00,190 --> 00:40:01,689 it just finally came loose. 1126 00:40:01,775 --> 00:40:04,067 I hate to see a nice damascus pattern like this 1127 00:40:04,152 --> 00:40:05,610 have something happen to it like that. 1128 00:40:05,695 --> 00:40:08,029 But, hey, it was a good fight, man. 1129 00:40:08,115 --> 00:40:13,243 ♪ ♪ 1130 00:40:13,328 --> 00:40:14,744 - we hate to see it, clay. 1131 00:40:14,830 --> 00:40:16,871 Unfortunately, your blade did succumb to this test. 1132 00:40:16,957 --> 00:40:18,873 But you're not out of the fight yet. 1133 00:40:18,959 --> 00:40:22,919 Devon, you have to survive six blows in the same test 1134 00:40:22,963 --> 00:40:25,547 to claim the title and the check for $10,000. 1135 00:40:25,632 --> 00:40:27,549 You ready? - Let's do it. 1136 00:40:27,634 --> 00:40:34,389 ♪ ♪ 1137 00:40:34,474 --> 00:40:37,392 - [grunting] 1138 00:40:37,477 --> 00:40:42,730 ♪ ♪ 1139 00:40:42,816 --> 00:40:44,482 - [exhales deeply] 1140 00:40:44,568 --> 00:40:50,780 ♪ ♪ 1141 00:40:56,621 --> 00:40:58,246 - well, devon, congratulations, man. 1142 00:40:58,331 --> 00:40:59,330 - Thank you. 1143 00:40:59,416 --> 00:41:01,374 - Clay, difficult test. 1144 00:41:01,460 --> 00:41:03,418 I want to say thank you so much for your hard work, 1145 00:41:03,503 --> 00:41:05,795 but, unfortunately, due to the catastrophic failure, 1146 00:41:05,881 --> 00:41:07,172 we couldn't continue the testing. 1147 00:41:07,257 --> 00:41:08,631 So, unfortunately, man, 1148 00:41:08,717 --> 00:41:10,258 your time here in the forge has ended. 1149 00:41:10,343 --> 00:41:11,759 I'm gonna have to ask you to please step out. 1150 00:41:11,845 --> 00:41:13,303 - Thank you. 1151 00:41:13,388 --> 00:41:14,846 I didn't expect that my blade was gonna break, 1152 00:41:14,931 --> 00:41:17,765 but ice is just a super-hard test 1153 00:41:17,851 --> 00:41:19,642 for any blade, no matter what. 1154 00:41:19,728 --> 00:41:21,394 Leaving here, I feel a lot more confident 1155 00:41:21,480 --> 00:41:24,314 'cause my ulu didn't break in a very tough challenge, 1156 00:41:24,399 --> 00:41:26,691 and my sword could keal. 1157 00:41:26,776 --> 00:41:28,943 ♪ ♪ 1158 00:41:29,029 --> 00:41:30,987 - well, devon, congratulations, man. 1159 00:41:31,072 --> 00:41:34,824 You are today's arctic forge champion. 1160 00:41:34,910 --> 00:41:36,534 You absolutely deserve it. 1161 00:41:36,620 --> 00:41:38,620 That is a brutal test, and you crushed it. 1162 00:41:38,705 --> 00:41:40,121 - Thank you. 1163 00:41:40,207 --> 00:41:41,998 I can't believe this just happened. 1164 00:41:42,083 --> 00:41:44,000 I am the "forged in fire" champion. 1165 00:41:44,044 --> 00:41:47,462 And I'm just thinking--all the support I've had from my wif. 1166 00:41:47,547 --> 00:41:49,714 My first plan is to take my wife to miami. 1167 00:41:49,799 --> 00:41:51,299 We're gonna get out of this cold weather 1168 00:41:51,384 --> 00:41:52,967 and go sit on the beach for at least four days 1169 00:41:53,053 --> 00:41:54,219 and just relax in the sunlight. 1170 00:41:54,304 --> 00:41:55,470 I'm very excited. 1171 00:41:55,555 --> 00:42:01,684 ♪ ♪