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[intense music]
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♪ ♪
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[rock music]
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♪ ♪
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- I'm trey wright, and I'm
from greenwood, mississippi.
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I love making
something of nothing,
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and that's why
I like forging,
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but the greatest joy
is raising my kids.
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The kids come out
and watch me work in the shop,
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and my oldest tells me
I need to do this,
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and I need to do that
because she's trying
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to emulate the competition
by critiquing my knives.
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[laughs]
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- my name is nathan sistare,
I'm 19 years old,
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and I'm from colorado.
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I'm a full-time student
studying biology
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to hopefully become
a veterinarian.
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I've always found bladesmithing
to be relaxing
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and helps me kind of deal
with college chemistry,
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and it's just fun
to hit hot metal.
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♪ ♪
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- I'm isaac gardner,
and I'm 24 years old.
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I'm a full-time jeweler.
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As a jeweler, there's
a lot of small detail work
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and making sure
that I have something that's,
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one, comfortable, two, strong
and, three, looks amazing.
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So as a bladesmith, I focus
on the same three aspects.
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♪ ♪
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- I'm paul sutt.
I'm from new jersey,
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and I'm a personal trainer.
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I've been
a lifelong martial artist
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and a weapons expert,
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and when I had the opportunity
to learn how to forge,
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I jumped on it
as fast as I could.
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It's just my passion.
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- Well, bladesmiths,
welcome to the forge.
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You guys were handpicked
for very unique
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and challenging
bladesmithing competition
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where we're going to test
all of your skills.
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Now, there's three rounds
of this competition.
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At the end of each one,
you're going to present
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your work
to our panel of expert judges.
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They're going to decide which
one of you will be leaving here
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$10,000 richer,
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carrying that tile of
"forged in fire" champion.
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The judges for today's
competition are
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abs master smith j. Neilson,
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historic weapons recreation
specialist, dave baker
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and edged-weapons
specialist doug marcaida.
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♪ ♪
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bladesmiths, you guys
are going to be
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taking part of a competition
we are calling the civil forge
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because the weapons,
the challenges, the testing,
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they're all inspired
by a period in american history
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that forged it
into what it is today.
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That is the civil war.
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Now, guys,
before we get into it,
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you have a decision to make.
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What kind of steel you want
to use to build your blades?
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You've got two options.
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♪ ♪
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you're gonna have to choose
between these bags of grapeshot
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and the cannonballs,
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both of which are good
high-carbon steel.
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- Oh, yeah.
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- Now, today we are not
going to ask you
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to build your signature blade
in your signature style.
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No, gentlemen,
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we've got something
much more interesting.
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I want you to build an iconic
blade from american history
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that's not so well
known today,
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but during its heyday
in the mid-19th century,
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it was very popular
and widely used.
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Gentlemen, you are going
to be building this...
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♪ ♪
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the arkansas toothpick.
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- Oh, yeah.
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- A popular weapon in the u.S.
During the mid-1800s,
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the arkansas toothpick was
a large double-edged dagger
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used by soldiers during
the american civil war.
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This versatile dagger was both
a practical survival knife
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and a combat weapon.
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The sharp, acute tip was
designed to inflict deep stabs
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and cuts in close quarters
with enemy combatants.
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It's rumored that
some soldiers were seen
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using the tip of the knife
as a toothpick,
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which is how it got its name.
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- Now, gentlemen, when you're
building your blades
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I need you
to follow these parameters.
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Your blades need to measure
between 12 and 14 inches.
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You need to have
a double-edged blade
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that has a dagger tip.
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Now, by the end of round one,
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you wanna be set up
for a coffin-style handle,
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and you need to be quenched
and hardened.
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- I've always had trouble
with daggers.
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They're a challenging knife.
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It's hard to keep them
symmetrical,
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so I just see
a real challenge ahead of me.
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- Now in round two
of the competition,
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you're going to add those
coffin handles,
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turning them
into fully functioning weapons,
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at which point,
we're gonna be testing
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for strength and durability
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in a test we like to call
"tilling the earth"
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and a log chop,
and then we're gonna check
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if your edge has held up
in a water canteen slice.
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You will have three hours in
round one of the competition,
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so work hard,
pay attention to the clock
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'cause your time starts now.
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[rock music]
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♪ ♪
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- so would you go
for the grapeshot,
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or would you go
for the cannonball?
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- I'd go for the cannonball,
just quick and easy.
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It's just a matter
of drawing it out
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and cutting off the excess
that you don't need.
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- Don't roll away, man.
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- The challenge with grapeshot
is the 1/4-inch balls
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that you put into a canister
with powder and steel.
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- Okay.
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I think my best bet
is gonna be to do canister.
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I don't wanna do
the cannonball
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because it's a big round
piece of metal
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and for this time competition
I think I'll be better off
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being able to control
how much material I have.
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I want to make my can
as far as possible,
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so I decided
not to use white out.
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I don't want to have
to peel it off later
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'cause that's just extra time
and energy wasted.
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- In a competition,
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unless you're asked
to peel the can, don't do it.
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- I gotta make this thing look
as good as possible.
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I'm going to make
canister damascus
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because I'm not messing
with that big old cannonball
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and trying to draw
a knife out of it.
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- Trey and nathan got their
cans in really quick.
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- That's because neither of
them used white out.
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- No, they didn't.
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- I've never made
a dagger before.
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I guess there's a first time
for everything,
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and it may as well be here.
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- If I won $10,000, I could
donate a portion of it
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to down's syndrome awareness.
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My youngest daughter
has down's syndrome
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and I'd like to spread
the knowledge
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that people with down's
syndrome are wonderful people.
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There's a stigma about it.
It's just not there.
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- So it looks like we're gonna
have two smiths
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who are going to go
the canister way
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and two
with just a ball of steel.
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- I've used canister damascus
and have had moderate results,
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where with the ball bearings,
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I've had good
results every time.
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- Look at what isaac is doing.
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See while that metal
is heating up in there,
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that's the time
to make your plan.
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- I know because
of my background in jewelry
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that the small details
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are what make a large project
come together,
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and so I'm careful to mark out
on my envelope my parameters.
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[whistling]
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♪ ♪
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- so right away I decide
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that I wanna go
with that cannonball.
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I've never made
a canister before.
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- A lot of the steel seems like
it's a lot easier
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than getting 100 forge welds
inside the canister.
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Prove a lot less likely
to have delamination.
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- All right.
Well, let's give it a shot.
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I want to just move
the metal a little.
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I'm not in a hurry.
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I know it's gonna
take a while to get that
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drawn into a nice billet.
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One more pass, and I'm good.
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♪ ♪
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- the initial forge weld
is the most important.
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If I don't set these welds,
it's gonna be bad.
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I'ma have to start all back
over or do something else.
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- It looks like trey is
compressing it down too cold.
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We've seen several times
where the canisters
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haven't been heated up enough.
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You start working on them,
and they start falling apart.
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- I think the welds are
setting.
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I'm feeling good.
I'm thinking everything
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is gonna be okay.
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- When you're setting a weld,
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your first couple of heats
need to be fairly gentle.
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- Very small presses
on his first pat,
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just like setting a weld
in anything else.
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You don't want
to stress the weld.
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- Feeling good.
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I think my weld took pretty
solidly, so keep on moving.
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- Bladesmiths, you guys have
two hours remaining.
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- Once I forged that cannonball
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down to some semblance
of a bar,
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the next thing
I'm gonna do is I'm gonna
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focus on the pre-form.
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- This particular dagger tapers
to a point.
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It doesn't go parallel lines
and then down to a point,
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so that's one thing hopefully
that they pay attention to
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in making this kind of dagger.
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- Right now I'm just bringing
down a taper to the point
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so that as I flatten it out
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I'm not gonna get
a big rectangular shape.
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I'm gonna get a nice
tapering dagger shape.
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That's all about moving
material to where I need it
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to minimize
the amount of grinding
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that I have to do in the end.
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♪ ♪
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- I'm gonna hammer
in the point,
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and we should be good.
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When I hammer the point in,
I have to be very careful
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'cause it's easy to mess
that point up
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an cause a big mushroom.
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In a competition like this,
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00:08:45,567 --> 00:08:47,526
you just can't afford
to make a bad mistake.
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- I've made a couple daggers.
Not great with the grind,
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00:08:53,825 --> 00:08:57,536
but, yeah,
I can forge the shape.
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- It looks like nathan
is working
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on the tip right now.
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- When you talk
about toothpick,
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00:09:01,250 --> 00:09:02,999
you think about poking
and stabbing,
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00:09:03,085 --> 00:09:05,835
so we want to have a strong tip
on this particular blade.
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00:09:05,879 --> 00:09:09,172
- The tilling the earth test
seems like a pretty easy test,
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just stabbing it in the ground,
but one of our
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00:09:11,009 --> 00:09:16,680
previous competitions
broke the first blade.
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- Mark, we got a problem.
- Pretty darn happy with that.
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♪ ♪
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- as I'm drawing out my blade,
I can see it starting to split.
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Mother[bleep].
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All: Ooh!
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- I don't know the way
the chunks are on the edges.
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Remember when trey did
his first initial forge weld,
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we were talking about
how the can wasn't hot enough?
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00:09:36,118 --> 00:09:37,867
- Mm-hmm.
- If you force it too much,
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it can start splitting
and separating.
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00:09:41,081 --> 00:09:42,706
- I still have a lot
of forging to do,
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00:09:42,791 --> 00:09:44,708
and it's barely enough time
to get that done.
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00:09:44,793 --> 00:09:46,751
I'm gonna have to use
every bit of know how
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00:09:46,837 --> 00:09:49,004
I know to fix these issues.
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00:09:49,089 --> 00:09:50,672
I can't start over now.
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00:09:50,757 --> 00:09:57,762
Damn it. Damn it. Damn it.
Damn it. Damn it.
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00:09:57,806 --> 00:09:59,097
- Anything he could be doing
at this point to fix that?
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00:09:59,141 --> 00:10:00,265
- I think just try
to grind them out.
246
00:10:00,350 --> 00:10:01,558
- I still have a lot
of forging to do,
247
00:10:01,643 --> 00:10:03,727
and I've got a lot of meat
left in this billet.
248
00:10:03,812 --> 00:10:05,937
I'm gonna mash it down
and draw it out,
249
00:10:06,023 --> 00:10:08,398
and then cut the cracks off.
250
00:10:08,483 --> 00:10:10,775
- That is looking rough.
- Yeah.
251
00:10:10,819 --> 00:10:13,069
Trey is trying to forge
weld it back together.
252
00:10:13,113 --> 00:10:14,487
He might squish it down.
253
00:10:14,573 --> 00:10:16,573
He might get it
looking like it's closed,
254
00:10:16,617 --> 00:10:17,949
but when he goes to grind it,
255
00:10:17,993 --> 00:10:21,077
they're
going to pop back up again.
256
00:10:21,121 --> 00:10:22,787
- Ohh!
257
00:10:22,831 --> 00:10:24,414
♪ ♪
258
00:10:24,458 --> 00:10:26,333
- you know,
I am pretty impressed
259
00:10:26,418 --> 00:10:28,793
with isaac's blade
at this point.
260
00:10:28,879 --> 00:10:30,587
- So far, I'm really happy
with my blade,
261
00:10:30,672 --> 00:10:34,215
the profile particularly.
262
00:10:34,301 --> 00:10:37,260
I checked the length, and I'm,
like, two inches short.
263
00:10:37,346 --> 00:10:39,304
The last thing I wanna do
is go home
264
00:10:39,348 --> 00:10:41,431
because I missed parameters.
265
00:10:41,475 --> 00:10:42,891
- Isaac went straight
to big blue
266
00:10:42,976 --> 00:10:44,726
and now he's trying to
draw it out further.
267
00:10:44,811 --> 00:10:47,979
- Hopefully he can draw out
that whole to 14 inches.
268
00:10:48,023 --> 00:10:49,439
- I'm taking extra care
to make sure
269
00:10:49,483 --> 00:10:50,774
that my blade is right
270
00:10:50,859 --> 00:10:53,943
where I need it
to be to hit parameters.
271
00:10:54,029 --> 00:10:57,822
- Bladesmiths, you have
1 hour remaining.
272
00:10:57,866 --> 00:11:01,034
- Still pretty thick.
The clock is ticking down,
273
00:11:01,119 --> 00:11:05,789
and I need to hog off a bunch
of steel before I quench it.
274
00:11:05,832 --> 00:11:07,999
- We got paul on the grinder,
275
00:11:08,085 --> 00:11:09,834
staring over his shoulder
at the clock.
276
00:11:09,878 --> 00:11:11,461
- It's very important
for me to make it
277
00:11:11,546 --> 00:11:13,505
to the testing round,
so I'm going to spend time
278
00:11:13,548 --> 00:11:15,674
and get this thing thinned out.
279
00:11:16,843 --> 00:11:19,344
♪ ♪
280
00:11:19,388 --> 00:11:20,512
- isaac's is in the quench.
281
00:11:20,555 --> 00:11:22,263
♪ ♪
282
00:11:22,349 --> 00:11:24,474
- whoo!
283
00:11:24,559 --> 00:11:26,685
The blade is hard,
and I'm ready
284
00:11:26,728 --> 00:11:29,354
to do some final grinding
on it.
285
00:11:29,398 --> 00:11:31,189
- It might seem like
a fairly simple blade,
286
00:11:31,233 --> 00:11:33,191
but there's four separate
bevels you got to work on.
287
00:11:33,235 --> 00:11:35,568
- It's a lot of precise work.
288
00:11:35,654 --> 00:11:37,862
- The difficulty here
is maintaining symmetry
289
00:11:37,906 --> 00:11:40,407
because if you grind one bevel
a little bit more
290
00:11:40,492 --> 00:11:41,908
than you did another one,
291
00:11:41,993 --> 00:11:44,035
it's not gonna anything
you want it to.
292
00:11:47,416 --> 00:11:49,708
- You think he got all his
delams out of the cracks?
293
00:11:52,337 --> 00:11:53,753
- Damn it.
294
00:11:53,839 --> 00:11:55,213
Those delams are still there.
295
00:11:55,298 --> 00:11:57,173
I'll have to fix
these issues
296
00:11:57,259 --> 00:11:59,050
in round two if I make it.
297
00:11:59,094 --> 00:12:01,302
Tim's winding down,
and I need to quench.
298
00:12:01,388 --> 00:12:03,513
♪ ♪
299
00:12:03,598 --> 00:12:06,141
the blade's hard,
and I'm happy.
300
00:12:06,226 --> 00:12:10,061
Now, I have to grind that can
off and grind in the bevel.
301
00:12:10,147 --> 00:12:11,688
I've never made
a dagger before.
302
00:12:11,732 --> 00:12:13,898
I'm used to grinding
two bevels, not four.
303
00:12:13,942 --> 00:12:16,067
This is challenging for me.
304
00:12:16,153 --> 00:12:18,778
- It's good he's not quitting,
305
00:12:18,864 --> 00:12:20,488
20 minutes.
306
00:12:20,574 --> 00:12:22,532
♪ ♪
307
00:12:22,576 --> 00:12:23,491
- nate's is quenched.
308
00:12:23,577 --> 00:12:25,326
♪ ♪
309
00:12:25,412 --> 00:12:27,412
- everything went well.
It stayed pretty straight,
310
00:12:27,456 --> 00:12:31,624
so I'm just gonna be
a happy camper and keep moving.
311
00:12:31,710 --> 00:12:33,084
[bleep].
312
00:12:33,128 --> 00:12:35,128
- Yowza.
- As I'm grinding,
313
00:12:35,213 --> 00:12:37,589
I realize
I have a bit of a warp.
314
00:12:37,632 --> 00:12:39,924
It's a pretty substantial
warp,
315
00:12:39,968 --> 00:12:42,761
I realize that it's too big
for me to grind out.
316
00:12:42,804 --> 00:12:46,055
So I get the rest of the blade
as clean as possible
317
00:12:46,141 --> 00:12:48,767
and hopefully get it to round
two and deal with it then.
318
00:12:50,562 --> 00:12:52,729
- Come on, baby.
319
00:12:52,814 --> 00:12:54,647
At this point,
I'm a little bit concerned
320
00:12:54,733 --> 00:12:57,025
'cause the clock's ticking
down.
321
00:12:57,110 --> 00:12:59,068
Yeah. That's good.
322
00:12:59,154 --> 00:13:01,279
- Paul's in the quench.
323
00:13:01,364 --> 00:13:04,073
- I'm just praying that
I have a hardened blade.
324
00:13:04,117 --> 00:13:06,826
Whoo!
325
00:13:06,912 --> 00:13:08,787
I don't wanna have
to quench this again.
326
00:13:10,791 --> 00:13:12,457
Whoo-hoo!
327
00:13:12,501 --> 00:13:14,209
It's hard, and it's good.
328
00:13:14,294 --> 00:13:15,835
♪ ♪
329
00:13:15,921 --> 00:13:20,673
- five, four, three, two, one.
330
00:13:20,759 --> 00:13:22,550
This round is over.
331
00:13:22,636 --> 00:13:24,260
♪ ♪
332
00:13:24,346 --> 00:13:27,222
- definitely a possibility that
this warp will send me home,
333
00:13:27,307 --> 00:13:29,724
but I hope that the judges
can overlook it
334
00:13:29,810 --> 00:13:32,644
and give me
another chance to fix it.
335
00:13:35,190 --> 00:13:36,940
- Well, gentlemen, you guys
all rose to the occasion
336
00:13:37,025 --> 00:13:38,817
of our civil war-themed
competition.
337
00:13:38,860 --> 00:13:41,194
You turned your grapeshot
or your cannonballs
338
00:13:41,279 --> 00:13:42,612
into arkansas toothpicks.
339
00:13:42,656 --> 00:13:43,780
But as you guys know,
340
00:13:43,824 --> 00:13:45,156
only three of you
are moving forward
341
00:13:45,242 --> 00:13:46,491
into round
two of the competition.
342
00:13:46,535 --> 00:13:47,742
So it's time for the judges
343
00:13:47,828 --> 00:13:49,494
to take a closer
look at your blades.
344
00:13:49,538 --> 00:13:51,663
Trey, you're up first.
Please present your blade.
345
00:13:51,706 --> 00:13:53,331
♪ ♪
346
00:13:53,375 --> 00:13:55,458
- all right. So, trey,
you went with the grapeshot,
347
00:13:55,544 --> 00:13:57,335
which is great,
and your blade actually
348
00:13:57,420 --> 00:13:59,128
wound up with a nice pattern.
349
00:13:59,214 --> 00:14:02,173
Right now though, your blade
is a little asymmetrical.
350
00:14:02,217 --> 00:14:05,927
You've got kind of a straight
side and then a bowed side.
351
00:14:06,012 --> 00:14:08,847
But what gives me pause
is right at the tang junction.
352
00:14:08,890 --> 00:14:12,600
I see delaminations
on both sides of the blade.
353
00:14:12,686 --> 00:14:15,353
If you do move forward,
you've got a grind to correct,
354
00:14:15,397 --> 00:14:18,690
and you've also got these
delaminations to take care of.
355
00:14:18,733 --> 00:14:20,358
- All right. Nathan, you ready?
- Yes, sir.
356
00:14:20,402 --> 00:14:22,694
- Please present your work.
357
00:14:22,737 --> 00:14:26,322
♪ ♪
358
00:14:26,366 --> 00:14:29,534
- all right, nathan,
your grinds look good.
359
00:14:29,578 --> 00:14:33,621
I don't see any seams
or delaminations anywhere.
360
00:14:33,707 --> 00:14:37,333
But there's one thing
that you really need to fix
361
00:14:37,419 --> 00:14:39,335
is the warp on the blade.
362
00:14:39,379 --> 00:14:41,838
But otherwise, good job.
- Thank you.
363
00:14:41,882 --> 00:14:43,381
- Isaac, you ready?
- Yes.
364
00:14:43,425 --> 00:14:45,300
- Please present your work.
365
00:14:45,385 --> 00:14:47,969
♪ ♪
366
00:14:48,054 --> 00:14:50,221
- all right. Isaac, let's talk
about your blade here.
367
00:14:50,265 --> 00:14:54,475
First up, it is the dagger
shape that we're looking for.
368
00:14:54,561 --> 00:14:57,562
You have a base that tapers
straight into the point,
369
00:14:57,606 --> 00:15:00,857
and your steel looks solid.
370
00:15:00,942 --> 00:15:03,026
Good job.
- Thank you.
371
00:15:03,111 --> 00:15:04,861
- All right, paul,
are you ready?
372
00:15:04,946 --> 00:15:07,572
- Yes, sir.
- Please present your work.
373
00:15:07,616 --> 00:15:10,575
♪ ♪
374
00:15:10,619 --> 00:15:12,076
- all right. Paul, you went
with the cannonball
375
00:15:12,162 --> 00:15:14,537
and there's still
a lot of weight to it.
376
00:15:14,623 --> 00:15:17,582
A good idea would be
to mark a centerline
377
00:15:17,626 --> 00:15:19,584
and bring these edges to it.
378
00:15:19,628 --> 00:15:22,629
That'll help you thin out
some material, more so.
379
00:15:22,714 --> 00:15:24,756
But otherwise, it looks solid
380
00:15:24,799 --> 00:15:25,715
and you still got a lot
to work with.
381
00:15:25,800 --> 00:15:28,092
Good job.
- Thank you.
382
00:15:28,136 --> 00:15:29,719
♪ ♪
383
00:15:29,804 --> 00:15:32,096
- well, gentlemen, I've gotta
say you've all presented
384
00:15:32,140 --> 00:15:34,933
a viable arkansas toothpick
for the judges to critique.
385
00:15:35,018 --> 00:15:37,268
But unfortunately, somebody
does have to go home today.
386
00:15:37,312 --> 00:15:41,731
The bladesmith leaving
the forge is...
387
00:15:41,775 --> 00:15:43,733
Trey.
388
00:15:43,818 --> 00:15:45,276
Your blade didn't make the cut,
389
00:15:45,320 --> 00:15:46,903
and doug's gonna
to tell you why.
390
00:15:46,988 --> 00:15:49,280
- Trey, for one who has never
made a dagger before,
391
00:15:49,324 --> 00:15:51,574
you came so close.
392
00:15:51,660 --> 00:15:53,451
But the asymmetrical shape
of your blade
393
00:15:53,495 --> 00:15:55,119
coupled with the visible
delaminations
394
00:15:55,163 --> 00:15:56,454
brings into question
395
00:15:56,498 --> 00:15:58,247
the structural integrity
of your blade.
396
00:15:58,333 --> 00:16:00,083
For those reasons
we're sending you home.
397
00:16:00,168 --> 00:16:02,460
- I understand.
- Well, trey,
398
00:16:02,545 --> 00:16:04,629
you should be
very proud of yourself.
399
00:16:04,673 --> 00:16:06,881
But unfortunately, I'm gonna
have to ask you, to please
400
00:16:06,967 --> 00:16:09,467
surrender your work
and step off the forge floor.
401
00:16:09,511 --> 00:16:11,386
♪ ♪
402
00:16:11,471 --> 00:16:13,471
- I'm leaving here sad because
I wanted to make it
403
00:16:13,515 --> 00:16:14,973
all the way through.
404
00:16:15,016 --> 00:16:17,266
But being my first time
making something like this,
405
00:16:17,352 --> 00:16:18,851
I'm very happy with it.
406
00:16:18,937 --> 00:16:20,979
Good luck, y'all.
- Well done.
407
00:16:21,064 --> 00:16:23,106
- I hope my daughters see if
you put your heart and soul
408
00:16:23,191 --> 00:16:25,024
into something
and try your best,
409
00:16:25,110 --> 00:16:27,819
the outcome will still be
something you can be proud of.
410
00:16:29,656 --> 00:16:31,572
♪ ♪
411
00:16:31,658 --> 00:16:33,324
- gentlemen, congratulations.
The three of you guys
412
00:16:33,368 --> 00:16:35,535
are moving forward into round
two of the competition,
413
00:16:35,620 --> 00:16:37,161
where you're going to add
handles to your blades,
414
00:16:37,205 --> 00:16:38,955
turning them into fully
functioning daggers.
415
00:16:39,040 --> 00:16:40,581
In this round you're
going to have to add
416
00:16:40,667 --> 00:16:43,126
a coffin-shaped handle
and a guard,
417
00:16:43,169 --> 00:16:45,753
and you're gonna need to use
a frame handle technique.
418
00:16:45,839 --> 00:16:47,463
At the end of this round,
the guys are going
419
00:16:47,507 --> 00:16:48,840
to put them to the test,
420
00:16:48,883 --> 00:16:50,383
checking for strength
and durability
421
00:16:50,468 --> 00:16:53,386
in our "tilling the earth"
and log chop,
422
00:16:53,471 --> 00:16:54,846
and we're going to check
the edge retention
423
00:16:54,889 --> 00:16:57,682
in a leather canteen slice.
424
00:16:57,726 --> 00:16:59,600
Gentlemen, you only have
two hours in round two
425
00:16:59,686 --> 00:17:01,561
of the competition,
so good luck.
426
00:17:01,646 --> 00:17:03,271
Your time starts now.
427
00:17:03,356 --> 00:17:05,648
♪ ♪
428
00:17:05,692 --> 00:17:06,983
- jay, a framed handle
429
00:17:07,027 --> 00:17:08,484
is something
I haven't seen before.
430
00:17:08,570 --> 00:17:10,695
Can you explain to me
what that all entails?
431
00:17:10,780 --> 00:17:12,155
- So you make a hidden tang.
432
00:17:12,198 --> 00:17:14,532
You slide the guard
up into place, set that,
433
00:17:14,617 --> 00:17:15,950
and you're going to make
a frame
434
00:17:16,036 --> 00:17:18,995
that goes around it
in that coffin shape.
435
00:17:19,039 --> 00:17:23,082
- All right. There are so many
things to do in this round.
436
00:17:23,168 --> 00:17:24,417
Creating a frame handle,
437
00:17:24,502 --> 00:17:26,085
something
I've never done before.
438
00:17:26,171 --> 00:17:29,380
Fitting a guard,
affixing a handle
439
00:17:29,466 --> 00:17:32,300
and it's a very short
amount of time.
440
00:17:32,385 --> 00:17:36,054
I focused first
on getting my guard fit up,
441
00:17:36,097 --> 00:17:38,014
then having my frame
and welding it together
442
00:17:38,099 --> 00:17:39,515
so that I can treat it
443
00:17:39,601 --> 00:17:44,896
like a regular
full-tang construction knife.
444
00:17:44,939 --> 00:17:48,733
- I'm concerned nathan
has a considerable warp.
445
00:17:48,777 --> 00:17:52,570
- I start trying to straighten
out my blade a little bit.
446
00:17:52,614 --> 00:17:55,239
I try to soften the middle
of my blade enough
447
00:17:55,325 --> 00:17:57,533
that I can bend it
without snapping it.
448
00:17:57,577 --> 00:17:58,993
- You've got to be very,
449
00:17:59,079 --> 00:18:01,079
very careful
heating that center ridgeline
450
00:18:01,122 --> 00:18:03,206
and not having that heat travel
up to the edges
451
00:18:03,291 --> 00:18:05,208
and lose your hardness.
452
00:18:05,293 --> 00:18:08,294
- Are you kidding me? It hasn't
really changed a whole lot.
453
00:18:08,379 --> 00:18:10,671
I've spent too much time
on it already,
454
00:18:10,757 --> 00:18:13,716
so I'm just going to move on
and hope for the best.
455
00:18:13,760 --> 00:18:16,677
[bleep].
456
00:18:16,763 --> 00:18:19,222
- So paul is getting
straight into his brain.
457
00:18:19,307 --> 00:18:22,058
- At home,
I never rush a handle,
458
00:18:22,143 --> 00:18:25,853
but I have to crack this thing
out as fast as I can.
459
00:18:25,939 --> 00:18:28,439
♪ ♪
460
00:18:31,611 --> 00:18:34,904
I realize that I didn't
leave myself enough
461
00:18:34,989 --> 00:18:36,948
for a good size handle.
462
00:18:36,991 --> 00:18:38,616
That's just not acceptable.
463
00:18:41,538 --> 00:18:42,745
- Oh, shoot.
464
00:18:42,831 --> 00:18:45,289
- Paul had to restart
on his frame.
465
00:18:45,375 --> 00:18:49,460
- Having a bad handle would be
a problem during testing.
466
00:18:49,546 --> 00:18:51,379
Ehh.
467
00:18:51,464 --> 00:18:53,923
- Bladesmiths, you guys have
an hour and 30 minutes
468
00:18:54,008 --> 00:18:55,466
remaining in round two,
469
00:18:55,510 --> 00:18:58,052
- and nathan's got some steel
for his frame.
470
00:18:58,138 --> 00:19:02,140
- My plan is to cut the shape
of my tang out of a piece
471
00:19:02,183 --> 00:19:06,894
of mild steel, slap it together
and make sure everything holds.
472
00:19:06,980 --> 00:19:08,479
Welding.
473
00:19:08,523 --> 00:19:09,647
♪ ♪
474
00:19:09,691 --> 00:19:12,316
feeling pretty good so far.
475
00:19:12,360 --> 00:19:15,153
- Nathan's got his frame
welded up.
476
00:19:15,196 --> 00:19:16,320
Now he's back over the band saw
477
00:19:16,406 --> 00:19:18,614
cutting out
the profile of his coffin.
478
00:19:18,658 --> 00:19:22,827
- Not as clean as I can make
it, but it'll have to do.
479
00:19:22,912 --> 00:19:26,414
- Gentlemen, you have
1 hour remaining.
480
00:19:26,499 --> 00:19:29,709
- At this point, I notice
that my guard is loose.
481
00:19:29,794 --> 00:19:31,127
[bleep].
482
00:19:31,212 --> 00:19:32,879
My heart drops.
483
00:19:32,964 --> 00:19:34,297
- I don't think isaac
is quite happy
484
00:19:34,340 --> 00:19:36,424
with the fitment of his guard.
485
00:19:36,509 --> 00:19:37,842
- I don't want to go home
486
00:19:37,927 --> 00:19:40,219
because a little piece
of brass wiggled loose.
487
00:19:40,305 --> 00:19:42,513
I know that I need
to figure something out.
488
00:19:42,557 --> 00:19:44,515
- A guard that's loose
will eventually per use
489
00:19:44,601 --> 00:19:46,517
is going to start
damaging the handle material.
490
00:19:46,561 --> 00:19:49,937
- As a jeweler, I set stones
into precious metals
491
00:19:50,023 --> 00:19:51,522
using a chisel.
492
00:19:51,566 --> 00:19:53,816
You hammer down all the way
around the perimeter
493
00:19:53,860 --> 00:19:55,526
and it pushes that metal down
494
00:19:55,612 --> 00:19:58,237
and it grabs on
to whatever is inside.
495
00:19:58,323 --> 00:19:59,864
- That brass being soft,
496
00:19:59,908 --> 00:20:01,991
that will compress it down
and close up that gap.
497
00:20:02,035 --> 00:20:03,326
- It works like a charm.
498
00:20:03,411 --> 00:20:04,368
I'm really happy with it.
499
00:20:04,454 --> 00:20:06,370
There we go.
500
00:20:06,414 --> 00:20:08,664
- It's time to work on
my scales.
501
00:20:08,708 --> 00:20:13,419
I'm looking to see if I can
find oak or a nice hard wood.
502
00:20:13,504 --> 00:20:15,213
I see some scales
that look nice,
503
00:20:15,256 --> 00:20:16,505
and I think
"well, let's give these a try."
504
00:20:18,551 --> 00:20:21,552
crap, did I just
break this stupid thing?
505
00:20:21,596 --> 00:20:23,763
The handle material cracked.
506
00:20:23,848 --> 00:20:25,306
Oh, come on.
507
00:20:25,391 --> 00:20:28,017
- He's using reconstituted
stone, it's very brittle.
508
00:20:28,061 --> 00:20:30,394
It's not really good
for an entire handle.
509
00:20:30,438 --> 00:20:32,188
- This is pointless.
510
00:20:32,232 --> 00:20:35,066
I'm already behind schedule
from where I was hoping to be.
511
00:20:35,109 --> 00:20:37,360
♪ ♪
512
00:20:37,445 --> 00:20:39,570
- this is where
you start freaking out.
513
00:20:39,614 --> 00:20:41,239
- As I'm looking at the clock,
I'm thinking,
514
00:20:41,282 --> 00:20:44,242
"there is no way I'm going to
be able to present
515
00:20:44,327 --> 00:20:46,452
a finished blade
to the judges."
516
00:20:46,537 --> 00:20:49,038
I am trying to think
of something
517
00:20:49,123 --> 00:20:50,665
to make this thing happen.
518
00:20:50,750 --> 00:20:55,962
[grunts]
519
00:20:56,047 --> 00:20:57,338
I need to start over again
on this.
520
00:20:57,423 --> 00:20:58,714
- I'm worried about paul.
There's still a lot of fit
521
00:20:58,800 --> 00:21:00,383
and finish
that needs to be done.
522
00:21:00,468 --> 00:21:03,344
- This is pointless. As I'm
looking through everything,
523
00:21:03,429 --> 00:21:05,388
I find
some beautiful acrylic.
524
00:21:05,473 --> 00:21:07,056
Let's give these a try.
525
00:21:07,141 --> 00:21:09,433
I have no idea if I'm gonna
be able to present
526
00:21:09,519 --> 00:21:13,229
a finished blade or not,
but I never quit.
527
00:21:13,273 --> 00:21:15,022
- Bladesmiths,
time is running out.
528
00:21:15,108 --> 00:21:17,525
You have 30 minutes remaining.
529
00:21:17,610 --> 00:21:20,319
- Now that I have my scales
glued on
530
00:21:20,405 --> 00:21:21,737
and waiting for that set,
531
00:21:21,823 --> 00:21:24,156
I'm gonna focus
on getting it sharp.
532
00:21:24,242 --> 00:21:26,784
I decided to do
an appleseed edge
533
00:21:26,828 --> 00:21:29,495
so that it can survive
being stabbed into rocks
534
00:21:29,580 --> 00:21:31,747
and chopped into a log.
535
00:21:31,833 --> 00:21:33,040
It's gonna be tough.
536
00:21:33,126 --> 00:21:35,209
♪ ♪
537
00:21:35,295 --> 00:21:37,336
- now he's got paper towels
taped up on his blade,
538
00:21:37,422 --> 00:21:38,754
so you know
he's got an edge right now.
539
00:21:38,840 --> 00:21:40,423
- So everything
is looking great.
540
00:21:40,508 --> 00:21:43,217
I know it's sharp
and I know it's ready to go,
541
00:21:43,303 --> 00:21:45,970
I still need
to shape my coffin handle.
542
00:21:46,055 --> 00:21:48,264
- I mean, that looks like
a steak knife handle.
543
00:21:48,349 --> 00:21:50,141
- So as I'm grinding,
I realize
544
00:21:50,184 --> 00:21:52,018
I may have removed
too much material
545
00:21:52,103 --> 00:21:53,561
and I'm really hoping
the judges
546
00:21:53,646 --> 00:21:54,979
are able to hold on tight.
547
00:21:57,358 --> 00:21:59,900
- Gentlemen, you've got
three minutes remaining.
548
00:21:59,986 --> 00:22:02,236
- Okay. Okay.
549
00:22:02,322 --> 00:22:04,238
Right now the handle
is where it's at.
550
00:22:04,324 --> 00:22:06,949
I can finally start
to get an edge on this thing.
551
00:22:07,035 --> 00:22:09,201
So as the clock
is ticking down,
552
00:22:09,287 --> 00:22:11,579
I'll be lucky
if I can get this thing done
553
00:22:11,664 --> 00:22:14,123
and get an edge on it in time.
554
00:22:14,208 --> 00:22:17,501
- Oh man, he's going
at a very aggressive angle.
555
00:22:17,545 --> 00:22:19,795
- There's a lot of steel
to be removed.
556
00:22:19,881 --> 00:22:22,673
I mean, the edges
were as thick as the border.
557
00:22:22,759 --> 00:22:25,468
- I think my blade will do
good in the strength test.
558
00:22:25,553 --> 00:22:28,137
I purposely left
a very beefy edge on it.
559
00:22:28,222 --> 00:22:29,972
- He might be thinking if he
has more meat on the blade
560
00:22:30,058 --> 00:22:31,390
the stronger that it'll be.
561
00:22:31,476 --> 00:22:32,683
- If you trust your heat
treatment,
562
00:22:32,769 --> 00:22:34,435
you don't need the math.
563
00:22:34,520 --> 00:22:35,978
- Meaty but good.
564
00:22:36,064 --> 00:22:37,646
♪ ♪
565
00:22:37,690 --> 00:22:42,568
- five, four, three, two, one.
566
00:22:42,653 --> 00:22:44,070
Gentlemen,
turn off your machines.
567
00:22:44,155 --> 00:22:46,781
Put down your tools.
This round is over.
568
00:22:46,866 --> 00:22:48,240
- Ahh!
569
00:22:48,326 --> 00:22:52,161
I can't believe I have
a nice finished blade.
570
00:22:52,246 --> 00:22:54,246
I never thought
I was going to be able
571
00:22:54,332 --> 00:22:57,041
to finish it in time,
but I did.
572
00:22:59,045 --> 00:23:01,504
- Bladesmiths, welcome
to our strength test.
573
00:23:01,589 --> 00:23:03,672
Our dual strength test
is going to be
574
00:23:03,758 --> 00:23:05,132
"tilling the earth"
575
00:23:05,218 --> 00:23:08,177
and then chopping
on the log above it.
576
00:23:08,262 --> 00:23:09,887
This is going to test
the edge holding ability
577
00:23:09,972 --> 00:23:13,265
and the overall construction
of the arkansas toothpick.
578
00:23:13,351 --> 00:23:15,351
Nathan, you're lucky enough
to be first.
579
00:23:15,436 --> 00:23:16,977
- Pitter, patter.
Let's get at her.
580
00:23:17,063 --> 00:23:18,854
- I like that.
581
00:23:18,940 --> 00:23:21,899
♪ ♪
582
00:23:21,943 --> 00:23:24,860
- I'm definitely worried about
the warp of my blade.
583
00:23:24,946 --> 00:23:27,988
If the point of my knife
catches a rock the wrong way,
584
00:23:28,074 --> 00:23:30,616
it's going to bend my blade
even more,
585
00:23:30,701 --> 00:23:33,035
if not completely snap off.
586
00:23:33,121 --> 00:23:39,583
It could definitely
send me home.
587
00:23:39,627 --> 00:23:41,043
I'm on the edge of my seat.
588
00:23:41,129 --> 00:23:41,961
It's just not something
you should do
589
00:23:42,046 --> 00:23:43,546
to a knife that you care about.
590
00:23:43,631 --> 00:23:44,255
♪ ♪
591
00:23:44,298 --> 00:23:47,591
- [grunting]
592
00:23:47,635 --> 00:23:54,557
♪ ♪
593
00:24:03,985 --> 00:24:05,860
hey, nathan. It survived.
Good job.
594
00:24:05,945 --> 00:24:08,946
Your edge held up pretty well,
but a couple issues.
595
00:24:08,990 --> 00:24:13,200
It lost a little bit
of the very tip on there.
596
00:24:13,286 --> 00:24:17,246
Nathan, you started with a warp
and it's still there.
597
00:24:17,290 --> 00:24:19,623
But overall, you survived.
Good job.
598
00:24:19,667 --> 00:24:21,584
- Thank you.
599
00:24:21,627 --> 00:24:23,502
- All right,
isaac, are you ready?
600
00:24:23,588 --> 00:24:25,045
- As ready as I will ever be.
601
00:24:25,131 --> 00:24:26,630
- Well, I'm ready now.
So let's go.
602
00:24:26,674 --> 00:24:29,967
♪ ♪
603
00:24:30,052 --> 00:24:32,470
- I can't feel anything
but my knees shaking.
604
00:24:32,513 --> 00:24:34,763
In that box there's rocks
and dirt
605
00:24:34,849 --> 00:24:36,307
and all sorts
of abrasive materials
606
00:24:36,392 --> 00:24:41,437
that can wear down an edge,
and that terrifies me.
607
00:24:41,522 --> 00:24:44,356
♪ ♪
608
00:24:44,442 --> 00:24:47,401
- [grunting]
609
00:24:47,487 --> 00:24:53,157
♪ ♪
610
00:24:55,870 --> 00:24:58,579
- it made it, isaac. Good job.
611
00:24:58,664 --> 00:25:00,539
I wished the handle
was just a little bit bigger,
612
00:25:00,625 --> 00:25:02,583
a little on the spindly side,
613
00:25:02,668 --> 00:25:04,919
but you got
the shape of the coffin good.
614
00:25:05,004 --> 00:25:08,005
You can see -- and I can
actually do that with my thumb.
615
00:25:08,049 --> 00:25:10,799
So you've lost the edge.
It's not a razor anymore.
616
00:25:10,885 --> 00:25:12,676
But overall, not bad at all.
Good job.
617
00:25:12,720 --> 00:25:13,802
- Thank you.
618
00:25:15,723 --> 00:25:17,806
- Ready, paul?
- Yes, sir.
619
00:25:17,892 --> 00:25:19,183
- All right. Let's do it.
620
00:25:19,227 --> 00:25:21,352
♪ ♪
621
00:25:21,395 --> 00:25:25,022
- after watching the other
two weapons be tested,
622
00:25:25,066 --> 00:25:27,399
I know that my blade
has to hold up
623
00:25:27,485 --> 00:25:31,028
and pretty much remain almost
perfect for me to make it.
624
00:25:31,072 --> 00:25:37,868
♪ ♪
625
00:25:38,454 --> 00:25:41,205
- [grunting]
626
00:25:41,249 --> 00:25:44,333
♪ ♪
627
00:25:48,422 --> 00:25:50,506
- it survived, paul.
- [exhales]
628
00:25:50,550 --> 00:25:52,883
- doing this log strike,
629
00:25:52,927 --> 00:25:56,554
you could hear how much heavier
this was striking a log,
630
00:25:56,597 --> 00:25:58,097
and instead of a thwack
it was more like
631
00:25:58,182 --> 00:26:00,558
an ax hitting something.
632
00:26:00,643 --> 00:26:02,768
But all in all, you survived.
Good job.
633
00:26:02,853 --> 00:26:06,355
- Thank you.
- Yeah. Sir.
634
00:26:06,440 --> 00:26:08,857
- Bladesmiths, this is
the sharpest test,
635
00:26:08,943 --> 00:26:12,194
the water canteen
stab and slice.
636
00:26:12,280 --> 00:26:13,904
I'm gonna take
your weapon, stab,
637
00:26:13,948 --> 00:26:16,907
and try to slice through
these leather water canteens.
638
00:26:16,993 --> 00:26:18,409
Nathan, you're up first.
Are you ready for this?
639
00:26:18,452 --> 00:26:20,411
- Yes, sir.
- All right. Let's do it.
640
00:26:20,454 --> 00:26:23,581
♪ ♪
641
00:26:27,086 --> 00:26:30,004
[intense music]
642
00:26:30,089 --> 00:26:36,927
♪ ♪
643
00:26:43,144 --> 00:26:44,893
all right, nathan,
let's talk about
644
00:26:44,937 --> 00:26:46,937
your arkansas toothpick here.
645
00:26:46,981 --> 00:26:49,106
First up, your tip.
646
00:26:49,150 --> 00:26:51,400
It took damage during the
strength test and it's rounded,
647
00:26:51,444 --> 00:26:54,153
and it's pushing the bag
all over the place.
648
00:26:54,238 --> 00:26:57,865
So overall, sir,
it kinda cuts.
649
00:26:57,950 --> 00:26:59,617
All right. Isaac, it's your
turn, sir. Are you ready?
650
00:26:59,702 --> 00:27:02,620
- I'm ready.
- All right. Let's do this.
651
00:27:02,663 --> 00:27:09,627
♪ ♪
652
00:27:13,299 --> 00:27:14,923
all right, isaac.
653
00:27:14,967 --> 00:27:18,177
First up, the angle you have,
right here, is acute enough
654
00:27:18,262 --> 00:27:21,972
to be able to push through
these water canteens.
655
00:27:22,016 --> 00:27:25,851
The edge did take some dulling,
but still enough to cut.
656
00:27:25,936 --> 00:27:29,772
Overall, sir,
your toothpick will cut.
657
00:27:29,857 --> 00:27:32,107
- Thank you.
- All right, paul,
658
00:27:32,193 --> 00:27:33,651
your turn, sir.
Are you ready?
659
00:27:33,736 --> 00:27:35,819
- Oh, yeah.
- All right. Let's do this.
660
00:27:35,863 --> 00:27:42,826
♪ ♪
661
00:27:45,873 --> 00:27:47,790
- good job.
662
00:27:47,875 --> 00:27:50,834
- All right, paul, let's talk
about your arkansas toothpick.
663
00:27:50,878 --> 00:27:54,004
It pierced nicely
through both canteens.
664
00:27:54,048 --> 00:27:56,256
But, because your blade
is very thick,
665
00:27:56,342 --> 00:27:59,176
the edge holding capability
of this is almost lost
666
00:27:59,220 --> 00:28:01,303
because I tried to cut
on the way out.
667
00:28:01,389 --> 00:28:03,722
Overall, sir, it will cut.
668
00:28:03,808 --> 00:28:06,517
- [exhales]
669
00:28:06,602 --> 00:28:08,185
- well, gentlemen,
all three of your blades
670
00:28:08,229 --> 00:28:10,104
made it through our strength
and our sharpness test,
671
00:28:10,189 --> 00:28:12,147
but as you know only two of you
are moving forward
672
00:28:12,233 --> 00:28:15,025
into the third round
of this competition.
673
00:28:15,069 --> 00:28:17,027
The bladesmith leaving
the forge is...
674
00:28:17,071 --> 00:28:20,864
♪ ♪
675
00:28:20,908 --> 00:28:22,366
nathan.
676
00:28:22,410 --> 00:28:24,368
Unfortunately, your blade
just didn't make the cut,
677
00:28:24,453 --> 00:28:27,204
and dave baker
is going to tell you why.
678
00:28:27,248 --> 00:28:28,997
- Nathan, I appreciate the work
you put in on that.
679
00:28:29,041 --> 00:28:31,500
I think your grinds
looked great.
680
00:28:31,544 --> 00:28:33,001
But the problem
was you had a warp
681
00:28:33,087 --> 00:28:35,546
that you just couldn't get out,
as well as the fact
682
00:28:35,589 --> 00:28:39,466
that you lost the tip
in that strength test.
683
00:28:39,552 --> 00:28:41,677
Those two things combined
just made a weapon
684
00:28:41,721 --> 00:28:43,053
that was ineffective.
685
00:28:43,097 --> 00:28:44,263
That's why
we're letting you go.
686
00:28:44,348 --> 00:28:46,515
- I understand.
- Well, nathan,
687
00:28:46,559 --> 00:28:47,850
you fought really hard
688
00:28:47,935 --> 00:28:49,393
in the first two rounds
of competition,
689
00:28:49,437 --> 00:28:51,186
but unfortunately
I'm going to have to ask you
690
00:28:51,272 --> 00:28:53,313
to please step off
the forge floor.
691
00:28:53,399 --> 00:28:55,399
♪ ♪
692
00:28:55,443 --> 00:28:58,444
- [sighs]
693
00:28:58,529 --> 00:29:00,571
I'm not gonna pretend
that I'm not disappointed,
694
00:29:00,614 --> 00:29:03,115
but I'm definitely leaving here
a better bladesmith
695
00:29:03,200 --> 00:29:05,033
than when I arrived,
696
00:29:05,119 --> 00:29:08,036
and when I get home I'm going
to make a couple more canister
697
00:29:08,080 --> 00:29:12,207
damascus arkansas toothpicks.
698
00:29:12,251 --> 00:29:14,042
- Well, paul, isaac,
congratulations.
699
00:29:14,128 --> 00:29:17,546
You are both moving forward to
round three of our competition.
700
00:29:17,590 --> 00:29:19,715
Now, you guys are heading back
to your home forges to work
701
00:29:19,800 --> 00:29:23,802
on yet another iconic weapon
from the civil war era,
702
00:29:23,888 --> 00:29:26,221
and that weapon is...
703
00:29:31,061 --> 00:29:36,148
Ulysses grant's donelson sword.
704
00:29:36,233 --> 00:29:38,275
- The donelson sword is
a commemorative blade
705
00:29:38,319 --> 00:29:40,444
ordered to
general ulysses s. Grant
706
00:29:40,488 --> 00:29:44,865
for his victory at fort
donelson in February of 1862.
707
00:29:44,950 --> 00:29:47,951
One of the first major union
victories of the civil war.
708
00:29:47,995 --> 00:29:49,578
The weapon features
a highly ornate handle
709
00:29:49,663 --> 00:29:51,121
and an engraved blade
710
00:29:51,207 --> 00:29:54,666
based on the popular
1860's officer's sword.
711
00:29:54,752 --> 00:29:57,127
After general grant's death,
his wife donated the sword
712
00:29:57,213 --> 00:30:00,005
to the smithsonian institute
in 1886,
713
00:30:00,090 --> 00:30:03,967
and it remains under their
care to this day.
714
00:30:04,053 --> 00:30:07,137
- As you can see this is a very
intricate and detailed blade,
715
00:30:07,181 --> 00:30:08,639
and when you come back
with your swords
716
00:30:08,682 --> 00:30:11,725
I want to see as much detail
as this one here.
717
00:30:11,811 --> 00:30:13,101
Your blade length
needs to measure
718
00:30:13,187 --> 00:30:16,438
between 29 and 31 inches.
719
00:30:16,482 --> 00:30:18,732
Your blades need
to be double edged.
720
00:30:18,818 --> 00:30:21,652
You need to have an upswept
rear quillon clamshell
721
00:30:21,695 --> 00:30:24,571
guard that faces
toward the tip, a knuckle-bow,
722
00:30:24,657 --> 00:30:28,784
and top it all off
with a urn-shaped pommel.
723
00:30:28,869 --> 00:30:30,744
- I'm really excited to
recreate
724
00:30:30,830 --> 00:30:32,496
one of history's
greatest weapons.
725
00:30:32,581 --> 00:30:34,665
I've never made anything
quite like this before
726
00:30:34,708 --> 00:30:36,667
with all the intricate
details and parts.
727
00:30:36,752 --> 00:30:39,837
I'm really intimidated
by what could be in store
728
00:30:39,880 --> 00:30:41,839
for me in this final round.
729
00:30:41,882 --> 00:30:44,299
- You have four days
to work on your swords.
730
00:30:44,343 --> 00:30:47,177
Good luck. See you then.
- [exhales]
731
00:30:48,514 --> 00:30:51,640
♪ ♪
732
00:30:51,725 --> 00:30:56,019
- today I need to get started
on forging and hopefully heat
733
00:30:56,063 --> 00:30:58,146
treating
general grant's donelson sword.
734
00:30:58,232 --> 00:31:00,023
That is one skinny sword.
735
00:31:00,109 --> 00:31:04,361
A build like this is pretty
far out of my comfort zone.
736
00:31:04,446 --> 00:31:06,864
I've made a grand total
of two swords in my life
737
00:31:06,907 --> 00:31:08,240
and I know that I'm going
738
00:31:08,325 --> 00:31:10,784
to have to push myself
to the brink.
739
00:31:10,870 --> 00:31:14,288
It's getting there.
It's time to quench it.
740
00:31:14,373 --> 00:31:17,207
♪ ♪
741
00:31:17,293 --> 00:31:21,003
[grunts] see, it's only going
to be hard to right there.
742
00:31:21,046 --> 00:31:25,591
That space between the tang
and the blade is not hardened.
743
00:31:25,676 --> 00:31:30,721
See the difference in tone?
My quench tank was too short.
744
00:31:30,764 --> 00:31:32,890
So I'm going to requench
my blade
745
00:31:32,933 --> 00:31:34,725
using a deeper quench tank
746
00:31:34,810 --> 00:31:37,477
so that I could quench it
all the way down.
747
00:31:37,563 --> 00:31:40,314
If those judges decide
to do a bend test on my sword,
748
00:31:40,399 --> 00:31:42,774
that soft area could take
a bend
749
00:31:42,860 --> 00:31:47,321
and not spring back to true,
and that's a big issue.
750
00:31:47,406 --> 00:31:48,906
[grunts]
751
00:31:51,452 --> 00:31:54,244
hopefully it came out
hard this time.
752
00:31:54,330 --> 00:31:57,915
That's hard. That's hard.
Oh, I feel so much better.
753
00:31:58,584 --> 00:32:01,710
♪ ♪
754
00:32:01,754 --> 00:32:03,754
- we're here back in lebanon,
new jersey,
755
00:32:03,797 --> 00:32:06,506
to make this amazing weapon.
756
00:32:06,592 --> 00:32:09,426
All right. Here we go.
This is the real mccoy now.
757
00:32:09,470 --> 00:32:11,345
So now that I'm back
at my home forge,
758
00:32:11,430 --> 00:32:13,889
I don't have any presses,
I don't have a power hammer.
759
00:32:13,974 --> 00:32:16,016
The only thing I have
is my hand
760
00:32:16,101 --> 00:32:19,102
and now it's just time
to hammer, hammer, hammer.
761
00:32:19,146 --> 00:32:22,064
My arm feels like jelly,
but there ain't no quitting.
762
00:32:22,149 --> 00:32:23,440
I've got to keep going.
763
00:32:23,484 --> 00:32:27,277
My right power hammer
is exhausted.
764
00:32:27,321 --> 00:32:29,529
Time to switch
to my left power hammer.
765
00:32:29,615 --> 00:32:33,200
I'm not nearly as far along
as I was hoping to be,
766
00:32:33,285 --> 00:32:35,911
but I'm actually happy the way
the steel is coming out.
767
00:32:35,955 --> 00:32:37,454
I guess that's
about it for today.
768
00:32:37,498 --> 00:32:38,956
♪ ♪
769
00:32:38,999 --> 00:32:40,624
- so today I'm feeling
really good
770
00:32:40,668 --> 00:32:42,793
about the point that I got to.
771
00:32:42,878 --> 00:32:45,587
Yeah.
That's got a nice spring to it.
772
00:32:45,673 --> 00:32:48,548
Today I hope to be able
to have the basic structure
773
00:32:48,634 --> 00:32:50,717
of my handle completed.
774
00:32:50,803 --> 00:32:55,639
I need the rear-facing quillon
and the two clamshell guards
775
00:32:55,724 --> 00:32:56,932
and the knuckle-bow.
776
00:32:56,976 --> 00:32:58,642
It's going to be
something like that.
777
00:32:58,727 --> 00:33:01,478
So now that I have
the components complete,
778
00:33:01,522 --> 00:33:03,605
I can move on
to welding them together.
779
00:33:03,691 --> 00:33:05,983
I'm really happy
with how it's looking.
780
00:33:06,026 --> 00:33:07,609
That's so cool.
781
00:33:08,988 --> 00:33:10,612
♪ ♪
782
00:33:10,698 --> 00:33:13,323
- day three, I got my puppy
for support,
783
00:33:13,367 --> 00:33:15,158
can't wait to get started.
784
00:33:15,244 --> 00:33:17,327
Yesterday, got the blade
just where I wanted it
785
00:33:17,371 --> 00:33:19,997
and I forged that thing out
right to specs.
786
00:33:20,082 --> 00:33:23,667
Boo ya! So we're getting close
to quench time.
787
00:33:23,711 --> 00:33:25,210
It's a little tricky for me
788
00:33:25,295 --> 00:33:27,504
because I've never done a blade
this thin before.
789
00:33:27,548 --> 00:33:30,132
I'm nervous as hell--
two whole days
790
00:33:30,217 --> 00:33:31,967
hammering this sword out.
791
00:33:32,052 --> 00:33:34,094
If something goes wrong
with the quench,
792
00:33:34,179 --> 00:33:40,684
there is no time
to do that again.
793
00:33:40,728 --> 00:33:42,352
Here we go.
794
00:33:42,396 --> 00:33:43,520
♪ ♪
795
00:33:43,605 --> 00:33:44,438
don't feel any tings
or pings or anything.
796
00:33:44,523 --> 00:33:47,065
I pull it out and I'm so happy.
797
00:33:47,151 --> 00:33:49,026
It looks straight.
It looks perfect.
798
00:33:49,069 --> 00:33:50,986
♪ ♪
799
00:33:51,071 --> 00:33:53,321
- so yesterday I was able
to get
800
00:33:53,407 --> 00:33:55,157
all of my handle
components assembled.
801
00:33:55,242 --> 00:33:56,825
It turned out really well.
802
00:33:56,869 --> 00:33:59,494
And now I need to beautify it.
803
00:33:59,580 --> 00:34:02,289
It's really ornate and complex.
804
00:34:02,374 --> 00:34:06,293
I cut in the channels for
my turquoise and amber inlay,
805
00:34:06,378 --> 00:34:07,627
and finally I moved on
806
00:34:07,713 --> 00:34:10,213
to masking the entire blade
with nail polish
807
00:34:10,257 --> 00:34:14,342
so that I can acid etch
those designs into the blade.
808
00:34:14,386 --> 00:34:16,261
There we go. Cool beans.
809
00:34:16,346 --> 00:34:18,346
I've worked really hard up
to this point
810
00:34:18,432 --> 00:34:23,852
and now I'm so happy with my
general grant's donelson sword.
811
00:34:25,147 --> 00:34:28,065
- Day four,
I'm absolutely exhausted.
812
00:34:28,108 --> 00:34:31,026
So now I'm going to do a little
bit of work on the clamshell,
813
00:34:31,111 --> 00:34:33,737
try to make it look as pretty
as I can as quick as I can,
814
00:34:33,822 --> 00:34:36,031
and then it's going to be
shaping the handle
815
00:34:36,116 --> 00:34:37,532
into a comfortable handle.
816
00:34:37,618 --> 00:34:40,077
Almost.
So I finally got all the pieces
817
00:34:40,120 --> 00:34:41,411
to fit on the tang.
818
00:34:41,455 --> 00:34:42,579
All right.
819
00:34:42,664 --> 00:34:45,040
This entire experience
has been more fun
820
00:34:45,125 --> 00:34:47,876
than I ever imagined
it would be.
821
00:34:47,920 --> 00:34:53,381
The blade is a little bit
chunky, but "it will keal."
822
00:34:53,467 --> 00:34:55,592
- isaac, paul,
welcome back to the forge.
823
00:34:55,636 --> 00:34:58,261
You guys had four days
to work on your versions
824
00:34:58,305 --> 00:35:00,222
of the general grant
donelson sword.
825
00:35:00,265 --> 00:35:01,598
But, before we get
to the testing,
826
00:35:01,683 --> 00:35:02,974
I want to hear
about your build.
827
00:35:03,060 --> 00:35:04,267
Paul, how did it go for you?
828
00:35:04,311 --> 00:35:06,394
♪ ♪
829
00:35:06,480 --> 00:35:09,773
- I took a piece of 5160 and
spent two days hammering it
830
00:35:09,858 --> 00:35:11,942
into the exact shape
that it is now,
831
00:35:12,027 --> 00:35:14,444
and all the components
were filed by hand.
832
00:35:14,530 --> 00:35:16,696
- It looks great.
Isaac, how did it go for you?
833
00:35:16,782 --> 00:35:18,573
♪ ♪
834
00:35:18,617 --> 00:35:20,534
- I also used 5160.
835
00:35:20,619 --> 00:35:22,911
I have some decorative acid
etching on the blade
836
00:35:22,996 --> 00:35:26,123
and some turquoise
and amber inlay into the hilt.
837
00:35:28,168 --> 00:35:30,460
- You did a phenomenal job.
Gentlemen,
838
00:35:30,504 --> 00:35:33,463
this is not only about beauty,
this is about strength.
839
00:35:33,507 --> 00:35:35,966
It's about sharpness.
It's about durability.
840
00:35:36,009 --> 00:35:37,968
One of you guys are going to be
leaving here the champion
841
00:35:38,053 --> 00:35:40,470
and we only know
one way to find that out.
842
00:35:40,556 --> 00:35:42,639
Up first, the keal.
Doug?
843
00:35:42,683 --> 00:35:46,476
♪ ♪
844
00:35:46,520 --> 00:35:48,979
- bladesmiths, welcome
to the keal test.
845
00:35:49,064 --> 00:35:52,107
The sword was made to be
a dueling-type of weapon,
846
00:35:52,192 --> 00:35:55,152
so I'm going to try to deliver
the same light slashes
847
00:35:55,237 --> 00:35:57,654
and thrusts
for this ballistics dummy.
848
00:35:57,739 --> 00:35:59,156
Paul, are you ready for this?
849
00:35:59,199 --> 00:36:01,074
- Oh, yes, sir.
- All right. Let's do this.
850
00:36:01,160 --> 00:36:03,535
♪ ♪
851
00:36:03,620 --> 00:36:07,622
- I hope my blade survives
because it is has been my dream
852
00:36:07,708 --> 00:36:13,837
to hear doug say,
"it will keal."
853
00:36:13,881 --> 00:36:16,840
[intense music]
854
00:36:16,884 --> 00:36:23,847
♪ ♪
855
00:36:33,108 --> 00:36:34,608
- all right, paul, let's talk
about your version
856
00:36:34,693 --> 00:36:36,943
of general grant's
donelson sword.
857
00:36:37,029 --> 00:36:41,489
The weight on this blade
is not that of a dueling sword
858
00:36:41,575 --> 00:36:42,824
because it requires
a little bit more
859
00:36:42,910 --> 00:36:46,161
than just wrist movement,
860
00:36:46,246 --> 00:36:48,496
but it is a great
cutting sword.
861
00:36:48,540 --> 00:36:50,707
Your edges are sharp.
862
00:36:50,792 --> 00:36:52,542
Even with the harassing cuts
you can see there,
863
00:36:52,628 --> 00:36:53,919
it cut deeply.
864
00:36:54,004 --> 00:36:58,215
And more importantly, sir,
it will keal.
865
00:36:58,300 --> 00:37:00,050
Isaac, your turn, sir.
Are you ready for this?
866
00:37:00,093 --> 00:37:03,511
- I guess.
- Okay. [laughs]
867
00:37:03,597 --> 00:37:07,933
- I'm feeling really nervous
about the strength of my blade.
868
00:37:08,018 --> 00:37:10,268
I know it's really thin
and it's really flexible
869
00:37:10,354 --> 00:37:12,145
and it's really
light and fast,
870
00:37:12,231 --> 00:37:13,355
but is it strong enough?
871
00:37:13,440 --> 00:37:15,482
Any number of things
could go wrong.
872
00:37:15,567 --> 00:37:18,485
[intense music]
873
00:37:18,570 --> 00:37:25,408
♪ ♪
874
00:37:35,462 --> 00:37:37,629
- all right. Isaac, let's talk
about your weapon here.
875
00:37:37,714 --> 00:37:39,798
What I like about it
is the time you took
876
00:37:39,883 --> 00:37:41,424
to put these details
877
00:37:41,510 --> 00:37:44,552
that we were asking
for on your sword.
878
00:37:44,596 --> 00:37:48,890
Everything cut was deep and not
a lot of power is required
879
00:37:48,976 --> 00:37:50,934
when you're swinging
something so light.
880
00:37:50,978 --> 00:37:54,562
But on probably hitting
the bone your blade
881
00:37:54,648 --> 00:37:58,275
did take a slight bend.
882
00:37:58,318 --> 00:38:02,112
But overall, sir,
your weapon will keal.
883
00:38:02,197 --> 00:38:03,613
- Thank you.
884
00:38:03,657 --> 00:38:05,991
♪ ♪
885
00:38:06,076 --> 00:38:07,575
- paul, isaac,
886
00:38:07,661 --> 00:38:09,452
you know what time it is.
Time for the strength test,
887
00:38:09,496 --> 00:38:12,622
a fan favorite,
the cringeworthy flex test.
888
00:38:14,418 --> 00:38:16,543
And we're going to flex
those blades to 35 degrees
889
00:38:16,628 --> 00:38:18,586
in either direction.
If you're still holding true,
890
00:38:18,672 --> 00:38:22,465
we're going to go to 45 degrees
in either direction.
891
00:38:22,551 --> 00:38:23,842
Paul, are you ready for this?
892
00:38:23,927 --> 00:38:25,885
- Not really. But go ahead
and bend away.
893
00:38:25,971 --> 00:38:27,387
- I'm going to.
894
00:38:27,472 --> 00:38:31,266
♪ ♪
895
00:38:31,310 --> 00:38:34,019
- so the bend test
really scares me.
896
00:38:34,104 --> 00:38:36,104
I've never made a blade
so thin
897
00:38:36,189 --> 00:38:39,399
and delicate that needed
to bend in each direction.
898
00:38:39,484 --> 00:38:41,985
My greatest fear
is that it will actually snap.
899
00:38:42,029 --> 00:38:49,075
♪ ♪
900
00:38:49,161 --> 00:38:51,161
♪ ♪
901
00:38:51,246 --> 00:38:52,329
- oh, my--
902
00:38:52,372 --> 00:38:57,876
♪ ♪
903
00:38:57,961 --> 00:38:59,836
- [exhales]
904
00:38:59,880 --> 00:39:06,843
♪ ♪
905
00:39:13,769 --> 00:39:15,268
- [grunting]
906
00:39:15,354 --> 00:39:17,020
- ohh!
907
00:39:19,858 --> 00:39:24,027
♪ ♪
908
00:39:24,071 --> 00:39:25,653
- so, paul, as far
909
00:39:25,739 --> 00:39:27,280
as the construction
of your blade goes,
910
00:39:27,366 --> 00:39:28,531
the handle is comfortable.
911
00:39:28,575 --> 00:39:30,992
We saw how well the sword cuts.
912
00:39:31,078 --> 00:39:34,496
You did a good job, but if you
look in to that blade,
913
00:39:34,581 --> 00:39:36,247
you can actually see
a dark spot
914
00:39:36,333 --> 00:39:38,291
on both sides of the blade,
915
00:39:38,377 --> 00:39:41,211
and whether that's a flaw
that you picked up
916
00:39:41,296 --> 00:39:44,798
in the forging process
or a flaw in the steel,
917
00:39:44,883 --> 00:39:46,674
I have no way of really
telling right now.
918
00:39:46,760 --> 00:39:48,635
The grain structure
on this looks fine.
919
00:39:48,720 --> 00:39:51,763
But having shattered,
having it pop like that,
920
00:39:51,848 --> 00:39:53,515
that's a big issue.
- Mm-hmm.
921
00:39:56,561 --> 00:39:58,895
♪ ♪
922
00:39:58,939 --> 00:40:00,730
- well, paul, we absolutely
hate to see that.
923
00:40:00,774 --> 00:40:02,732
You put a lot of work
into your blade.
924
00:40:02,776 --> 00:40:05,443
You made it past the 35
on both sides,
925
00:40:05,529 --> 00:40:07,529
but you did break
on the way to 45.
926
00:40:07,572 --> 00:40:09,447
But you're not out
of the fight yet.
927
00:40:09,533 --> 00:40:12,492
Isaac, you've got to survive
both of the 35-degree turns,
928
00:40:12,577 --> 00:40:14,953
as well as the official
ruling of 40 degrees
929
00:40:15,038 --> 00:40:17,205
towards the south.
- [sighs]
930
00:40:17,290 --> 00:40:19,416
my heart is in my throat.
931
00:40:19,459 --> 00:40:21,709
This is literally
make or break.
932
00:40:24,256 --> 00:40:27,257
[tense music]
933
00:40:27,300 --> 00:40:34,097
♪ ♪
934
00:40:51,616 --> 00:40:53,158
[exhales]
935
00:40:53,243 --> 00:40:55,618
- congratulations, man.
- Thanks.
936
00:40:55,662 --> 00:41:01,291
♪ ♪
937
00:41:01,334 --> 00:41:03,460
- paul, I want to say thank you
for your hard work.
938
00:41:03,503 --> 00:41:05,378
You have what it takes
to fight in this forge.
939
00:41:05,464 --> 00:41:07,005
Unfortunately,
I'm going to have to ask you
940
00:41:07,090 --> 00:41:08,798
to please step off
the forge floor.
941
00:41:08,842 --> 00:41:11,009
- Thank you, gentlemen.
It was an honor.
942
00:41:11,094 --> 00:41:12,927
- Great job.
943
00:41:13,013 --> 00:41:15,221
- Of course, I'm disappointed
that I didn't win,
944
00:41:15,307 --> 00:41:18,224
but I am very proud
of the blade that I made,
945
00:41:18,310 --> 00:41:19,767
and I had the best time.
946
00:41:19,853 --> 00:41:21,728
This was such a good
experience,
947
00:41:21,813 --> 00:41:24,814
and it was an honor to compete
against such a good competitor.
948
00:41:24,858 --> 00:41:27,734
♪ ♪
949
00:41:27,819 --> 00:41:30,487
- isaac, we asked you to build
general grant's donelson sword.
950
00:41:30,530 --> 00:41:33,323
You performed phenomenally
and built us something
951
00:41:33,366 --> 00:41:34,824
that is not only functional,
952
00:41:34,868 --> 00:41:37,827
but absolutely beautiful
and stunning to look at.
953
00:41:37,871 --> 00:41:40,497
You are the "forged
in fire" champion,
954
00:41:40,582 --> 00:41:42,582
and you just earned yourself
a check for $10,000.
955
00:41:42,667 --> 00:41:44,167
Congratulations.
956
00:41:44,211 --> 00:41:47,003
- I'm the "forged in fire"
champion, baby! Whoo!
957
00:41:47,047 --> 00:41:48,546
[applause]
958
00:41:48,632 --> 00:41:51,174
- how do you feel?
- Cloud nine.
959
00:41:51,218 --> 00:41:52,509
I'm feeling so good.
960
00:41:52,552 --> 00:41:54,302
- That's a remarkable
piece of work,
961
00:41:54,387 --> 00:41:55,845
and you should be
incredibly proud of it.
962
00:41:55,931 --> 00:41:57,639
- Thank you.
963
00:41:57,724 --> 00:41:59,474
There's just too many feelings
going through my head
964
00:41:59,559 --> 00:42:04,312
and my heart to really process
what's all happening right now.
965
00:42:04,397 --> 00:42:07,023
I can't believe it.
I'm feeling so good.
966
00:42:07,067 --> 00:42:12,195
♪ ♪