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[dramatic music]
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♪ ♪
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- my name is eric himker.
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I'm 29 years old,
and I'm a design engineer.
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I design seat structures
for cars,
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and it's very important
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because if the person
is not comfortable,
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they're not gonna
buy that car.
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Same thing goes for a knife.
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If that is not comfortable,
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they're not gonna
wield that knife.
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♪ ♪
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- my name is dave armor, and
I am from auburn, illinois.
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I got into bladesmithing
when I was 15.
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I went to a theme park where
they had a gun and knife shop,
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and a man was demonstrating
how to make a knife.
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Being 15
and just being fascinated,
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I followed him into his shop
and asked so many questions,
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he literally took a book
on knifemaking
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that was for sale,
threw it at me
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and said get the hell
out of his shop.
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- Hi, I'm martin sack.
I'm 52 years old.
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I started training
in martial arts in 1975.
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I'm a senior professor in the
art of american kempo karat,
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and that's
what kind of led me
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to the bladesmithing
portion of it.
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I want to recreate
ancient martial arts weaponry.
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It just goes hand-in-hand.
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♪ ♪
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- my name is jimmy riley.
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I'm 33, and I am
a full-time welding teacher
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at my local high school.
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I love my welding
instructor job.
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The opportunity to teach
the next generation
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and inspire them
into making things
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is the greatest thing
that I've ever done.
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♪ ♪
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- bladesmiths,
welcome to the forge.
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We've got three
very intense rounds
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of bladesmithing competition
for you.
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At the end of each round,
you're gonna present your work
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to our panel of expert judges.
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The men behind me are the ones
who will decide
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which one of you
is gonna be leaving here
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carrying the title
of "forged in fire" champion
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and pockets full of $10,000.
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Today, they are
abs master smith j. Neilson,
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historic weapons re-creation
specialist dave baker,
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and edged weapon
specialist doug marcaida.
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Bladesmiths,
throughout history,
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there have been cultures that
have truly immersed themselves
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in the artistry
that is bladesmithing.
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Today, in the forge,
we are gonna be highlighting
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the korean heritage.
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Every aspect
of this competition,
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we are gonna be
honoring their culture,
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whether it's the tests,
the techniques,
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or the weapons
we're having you build.
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As you see next to me, we have
a yin-yang on the floor.
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The yin-yang represents
the delicate balance
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between two opposing forces.
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When it comes
to bladesmithing,
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there are no two
opposing forces
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that hold more importance
than fire and water.
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Behind each of you,
there is a water tank.
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The koreans have mastered
the art of the water quench,
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an extremely delicate process
that, when done properly,
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ends with an extremely strong
and durable blade.
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If you make a mistake,
you'll end up with cracks,
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with fissures or a blade
that could just shatter.
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In this competition, we have
gotten rid of the oil buckets.
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We're gonna ask
for a water quench.
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- Ah, crap.
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It's very dangerous
to quench in water.
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You can get a crack.
You can get a warp.
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You can get a crack and a warp.
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Many, many things
can go wrong.
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- You're probably wondering
what am I going
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to be quenching in water.
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We want you to build this.
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♪ ♪
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the hwando sword.
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- The hwando is a single-edged
battle-worthy sword
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of the korean military
during the joseon dynasty
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between the 12th
and 19th centuries.
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During the imjin war,
the sword was modified
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and forged to sharper
and longer
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to battle
the invading japanese.
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The hwando's lightweight
and compact size
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provided the korean warriors
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with a fast
and effective weapon
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capable of delivering cuts
with precision
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and ease of recovery.
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Although the size and form
differed in diverse period,
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the single-edged, slightly
curved blade is constant.
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It is prominently used
in the recent netflix
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hit series "kingdom."
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- now, gentlemen,
here to tell you about it
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is a bladesmith
who made this blade,
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an extremely talented
korean-american bladesmith
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who just so happens to also be
a "forged in fire" champion:
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Boyd ritter.
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- I really wanted
to build a hwando
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because there's a lot
of versatility in this sword.
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It is designed
as a secondary weapon
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for close-quarter combat.
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It's a very sleek weapon,
but the action is incredible.
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It's been enriching
to dig into
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my own heritage a little bit,
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learning all of this history
and realize
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that you're a part of it.
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It's just been really cool.
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Whew!
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- Guys, we want you
to recreate this blade
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down to the finest of details.
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In order for you to be set up
for round two,
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we're going to be supplying you
with the habakis.
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On your workstations, we have
supplied you with w1 steel,
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which you must use
to make your hwando swords.
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Moving into round two,
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you're going to add handles
to your blades,
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turning them into
fully functioning weapons,
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at which point the judges
are going to be testing
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for strength and durability
in a wax wood staff attack
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and for edge or tension
in a rubber tube slice.
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You have three hours on
the clock, so good luck.
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Your time starts now.
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♪ ♪
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- this is going to be fun.
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- So we asked these guys
to make boyd ritter's hwand.
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- That's a gorgeous piece.
It must have been fun for boyd
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doing something from
his own cultural history.
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♪ ♪
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- you could probably get
at least three of these hwandos
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out of that chunk of steel,
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so I'm going to start out
with half of it.
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I have zero experience
with any sort of eastern asian
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blades of any kind,
but as an engineer,
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one of the strengths
that we have to do
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is develop strategies
to overcome a problem.
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- Is this a ceremonial blade,
or is this a fighting weapo?
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- No, it's a fighting weapon
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during the joseon period
of korea.
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The koreans were
more militaristic,
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where they saw the sword
as a tool.
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♪ ♪
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- jimmy has got his steel cut
in half and in the forge,
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and he just cut a sliver off
what's left of the w1 he ha.
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- I have never attempted
a water quench,
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but I know that it's going
to introduce tons of crack.
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I don't want any of that
to happen, so I test it.
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- W stands for water.
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It's a more forgiving metal
to be quenched in water,
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but that's a very smart move
on jimmy's part.
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If you haven't
done this before,
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do your trial-and-error
right now.
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♪ ♪
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- when I put it in the vice
and cinch it down,
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it breaks under the pressure
of the vice.
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- That snapped real easy.
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- I know immediately
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that the steel is very brittle
out of the quench.
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I'm going to have
to thermocycle my blade
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a couple times
before I quench it.
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♪ ♪
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- they gave us a really large
piece of steel,
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but I'm not sure how much of it
I need for a piece,
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so I'm going to just forge out
off of it as much as I need.
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- After that first heat,
you're going to be able
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to draw that cylinder out
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the length of this blade
then cut it to shape.
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- I've worked with w1.
It's forgiving,
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but it's also got
a little bit of a trick.
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You get it a little too cold
or a little too hot,
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or you get a little
aggressive hitting it,
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you're going to have
some problems.
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♪ ♪
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- my game plan
is to draw the steel out
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almost to the full length
I need it to be
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and then work
on the width parameters.
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I have some experience
in korean martial arts,
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but I've never made
a hwando sword before.
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- This is a fairly
simple shape of a knife.
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If you look at the spine,
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it's virtually straight
until the end,
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where it has a bit of
an upkick at the tip.
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- It's in my wheelhouse.
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I understand these blades.
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I own several of them,
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and I feel that I'll be able
to replicate that.
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♪ ♪
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- as an engineer,
it's very important
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to leave myself enough room
to be able
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to make the next step
even that much more precise.
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- It looks like eric has
a piece of quarter-inch stel
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as a stopper in the press.
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- Well, that's a smart idea.
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- The kiss block
on the die of the press
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makes it really easy for me
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to draw out the steel
to a quarter-inch thickness.
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It's just going to save me
that much time down the road
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instead of having
to forge it way thicker
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and grind it all back,
or forge too thin
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and not be able
to make the blade
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as thick as I would like.
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- Doug, you're always talking
about forging thick,
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grinding thin.
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Would this be a time when
they would want to forge it
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to shape pretty thick,
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so when they
go in the water quench,
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it doesn't shock the inside
and then grind it down?
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- Yes.
- Feeling good, looking good!
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00:08:29,259 --> 00:08:31,885
- Bladesmiths, you're down
to two hours remaining
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in round one!
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- I'm trying to only work
the first half of the cylinder.
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That way, if I really screw
it up and I have to cut off,
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I can just start pressing
that down
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00:08:42,397 --> 00:08:44,856
and lengthening the piece
that I've already got.
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00:08:44,900 --> 00:08:46,858
- Yeah, I'd be putting that
back in a fire,
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especially on a water quench.
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You don't want to work
the steel too cold,
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because you could actually
pound stress fractures
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into the steel that will
open up when it hits the water.
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- The big challenge
with this round
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is everything
has to be dialed in,
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so I'm going to take my time,
double-check things
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and hopefully get it right.
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♪ ♪
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- now that the billet is
a little bit more manageable,
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I can start to work
on the development of the tang.
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- A large part
of this challenge,
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other than the water quench,
is the habaki.
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- Yep.
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00:09:20,936 --> 00:09:24,020
- Adding the habaki does add
a level of difficulty
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because you need to make sure
your shoulders are correct
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so that everything slides up to
it and marries nice and tight.
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Where's the time check, grady?
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[laughter]
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00:09:34,658 --> 00:09:38,368
- bladesmiths, you guys have
90 minutes remaining!
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00:09:38,453 --> 00:09:39,786
♪ ♪
241
00:09:39,871 --> 00:09:41,788
- I got to get one of those.
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00:09:41,873 --> 00:09:45,041
- Look how thin
jimmy's blade is.
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00:09:45,127 --> 00:09:46,710
- My billet's getting
pretty long,
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00:09:46,795 --> 00:09:49,296
and the thickness is a little
under
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00:09:49,381 --> 00:09:50,922
what I would like it to be,
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so I go ahead and take off
a pretty good size
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before I actually start
shaping the blade.
248
00:09:55,137 --> 00:09:56,595
So they give us a habaki,
249
00:09:56,638 --> 00:09:58,305
which I'm immediately
grateful for,
250
00:09:58,390 --> 00:10:01,766
because that alone
is two or three hours of work,
251
00:10:01,852 --> 00:10:04,894
but the catch-22 is that we
have to tailor-make this blae
252
00:10:04,980 --> 00:10:07,397
around an existing piece.
253
00:10:07,482 --> 00:10:09,608
- He's got a super-thin
profile blade.
254
00:10:09,693 --> 00:10:12,444
- Yeah, is his blade going to
be too thin for that habaki,
255
00:10:12,529 --> 00:10:14,321
which is going
to force him to make one?
256
00:10:14,406 --> 00:10:17,157
♪ ♪
257
00:10:17,242 --> 00:10:18,742
- all righty.
258
00:10:18,827 --> 00:10:21,661
I feel like I've got it drawn
out to the size I need.
259
00:10:21,747 --> 00:10:25,415
I'm going to start
hammering it to shape.
260
00:10:25,500 --> 00:10:27,125
[sighs]
261
00:10:27,210 --> 00:10:28,960
as I'm working the steel,
my arms are tired.
262
00:10:29,046 --> 00:10:30,795
My hands are tired.
263
00:10:30,881 --> 00:10:33,173
Time to cut it off
and start forming the point
264
00:10:33,258 --> 00:10:36,009
and to make this actually
look like a sword.
265
00:10:36,094 --> 00:10:37,636
♪ ♪
266
00:10:37,721 --> 00:10:40,930
- jimmy's blade
is still super narrow.
267
00:10:41,016 --> 00:10:43,224
- So the blade is
pretty close to the part
268
00:10:43,310 --> 00:10:45,393
where I need
to start thermocycling
269
00:10:45,479 --> 00:10:47,854
and start thinking
about the quench.
270
00:10:47,939 --> 00:10:49,356
♪ ♪
271
00:10:49,441 --> 00:10:50,690
both: Oh!
272
00:10:50,776 --> 00:10:53,318
- Jimmy's blade got so hot,
273
00:10:53,403 --> 00:10:55,612
when he's pulling it out,
it fell in two.
274
00:10:55,697 --> 00:10:58,323
- You know how thin that blade
had to be for that to happe?
275
00:10:58,367 --> 00:10:59,741
- Exactly.
276
00:10:59,826 --> 00:11:01,826
- My heart falls
and hits the floor.
277
00:11:01,912 --> 00:11:06,247
W1 is one of those steels
that if you do anything to it
278
00:11:06,333 --> 00:11:10,335
at too high a temperature,
it will stress that metal.
279
00:11:10,420 --> 00:11:12,879
- I'm about halfway through
the clock at this point,
280
00:11:12,964 --> 00:11:15,256
and I'm distraught
and confused
281
00:11:15,342 --> 00:11:17,717
and I am definitely
feeling the heat.
282
00:11:17,803 --> 00:11:20,220
There's just
nothing left of it.
283
00:11:20,305 --> 00:11:27,102
Ah!
284
00:11:27,145 --> 00:11:28,311
And my sword melts in half.
285
00:11:30,357 --> 00:11:32,399
Ah!
Starting over!
286
00:11:32,484 --> 00:11:35,568
There is not an ounce
of quit in me.
287
00:11:35,654 --> 00:11:37,612
All right, all right,
all right, all right.
288
00:11:37,698 --> 00:11:40,573
Calm down, calm down.
289
00:11:40,659 --> 00:11:43,827
Today's challenge is all
about balance, yin and yang.
290
00:11:43,912 --> 00:11:45,704
You know,
peace and storm,
291
00:11:45,747 --> 00:11:48,373
so I know that I need
to center myself
292
00:11:48,458 --> 00:11:50,375
and calm down a little bit.
293
00:11:50,460 --> 00:11:51,918
Just a little bit of panic.
- You got it, dude.
294
00:11:52,003 --> 00:11:54,504
- Just a little bit of panic.
295
00:11:54,589 --> 00:11:55,922
♪ ♪
296
00:11:56,007 --> 00:11:57,841
- eric's blade's
looking nice over there.
297
00:11:57,926 --> 00:12:00,051
- I feel like
time's flying by,
298
00:12:00,137 --> 00:12:02,220
so at this point,
I start the thermocycles.
299
00:12:02,305 --> 00:12:04,723
I know that doing the
thermocycling on this blade
300
00:12:04,808 --> 00:12:06,057
is going to at least help
301
00:12:06,143 --> 00:12:07,767
with relieving
some of that stress
302
00:12:07,853 --> 00:12:09,561
before it goes in
for the quench.
303
00:12:09,646 --> 00:12:11,062
How are you doing, dave?
304
00:12:11,148 --> 00:12:12,897
- I'm going to try to get
this heat halfway even
305
00:12:12,983 --> 00:12:14,566
so I can normalize it.
306
00:12:14,651 --> 00:12:17,402
- All right, eric and dave both
doing rounds of thermocycling,
307
00:12:17,487 --> 00:12:18,862
so if somebody goes
and quenches today
308
00:12:18,947 --> 00:12:20,572
without doing the proper
thermocycling,
309
00:12:20,615 --> 00:12:22,073
we're going to see cracks.
310
00:12:22,159 --> 00:12:24,909
- Oh, probably, yeah.
I'd put money on it.
311
00:12:24,995 --> 00:12:28,037
- Gentlemen, you have
one hour remaining!
312
00:12:28,123 --> 00:12:29,748
♪ ♪
313
00:12:29,833 --> 00:12:32,208
- so I start to do
my thermocycle on the blade,
314
00:12:32,252 --> 00:12:34,252
and I notice that because
there's a little bit
315
00:12:34,337 --> 00:12:37,380
more beef in the tip,
it starts to warp.
316
00:12:37,466 --> 00:12:38,965
♪ ♪
317
00:12:39,050 --> 00:12:41,301
it's warping like crazy.
318
00:12:41,386 --> 00:12:42,969
I know I need to correct that.
319
00:12:43,054 --> 00:12:45,180
I bring it over
to the post vice,
320
00:12:45,265 --> 00:12:47,307
and I kind of use that
very gently
321
00:12:47,392 --> 00:12:49,058
just to align everything.
322
00:12:49,144 --> 00:12:51,561
I wanted to thermocycle
a few more times,
323
00:12:51,646 --> 00:12:53,605
but I don't have
the time to do that.
324
00:12:53,690 --> 00:12:56,149
I need to really focus
on fixing this warp.
325
00:12:56,234 --> 00:12:59,152
Lord willing,
I make it to round wwo.
326
00:12:59,237 --> 00:13:01,780
- Guys, if I've learned
one thing in this forge so far,
327
00:13:01,865 --> 00:13:04,157
it's water quenches are bad.
328
00:13:04,242 --> 00:13:05,617
- Water quenching
is actually a technique
329
00:13:05,660 --> 00:13:07,035
that's been used forever.
330
00:13:07,120 --> 00:13:08,328
You can get away with it.
331
00:13:08,413 --> 00:13:09,704
Add salt,
and then you add the brine.
332
00:13:09,790 --> 00:13:11,581
It makes it a little bit safer.
333
00:13:11,666 --> 00:13:15,460
And dave took like 3 or 4 cups
of salt and put it in his tank.
334
00:13:15,545 --> 00:13:17,045
- Adding salt to the water
335
00:13:17,130 --> 00:13:19,130
slows down the quench speed
a little bit,
336
00:13:19,174 --> 00:13:20,840
so I just throw
a whole bunch in there,
337
00:13:20,926 --> 00:13:22,383
and hopefully,
I've got enough in it.
338
00:13:22,469 --> 00:13:24,260
I realistically
only have one chance
339
00:13:24,346 --> 00:13:25,720
to get this quench right.
340
00:13:25,806 --> 00:13:28,848
It's not like oil where
I can go back and re-quench
341
00:13:28,934 --> 00:13:30,517
if I don't get it hard enough.
342
00:13:30,602 --> 00:13:32,227
It's do it now.
This is the blade I've got.
343
00:13:32,312 --> 00:13:33,728
All right, guys.
344
00:13:33,814 --> 00:13:35,939
Hold onto your butts.
Here it goes.
345
00:13:36,024 --> 00:13:37,732
- Drumroll, everyone.
- Oh!
346
00:13:37,818 --> 00:13:39,609
- Do it, do it, do it.
- Here we go.
347
00:13:39,694 --> 00:13:44,280
♪ ♪
348
00:13:44,366 --> 00:13:46,783
- straight!
- Nice!
349
00:13:46,868 --> 00:13:49,452
- Now we just got to find out
if I really cracked it.
350
00:13:49,538 --> 00:13:52,455
♪ ♪
351
00:13:52,541 --> 00:13:55,041
- all right, well, jimmy drew
that steel down pretty quickl.
352
00:13:55,126 --> 00:13:56,626
That's good.
353
00:13:56,711 --> 00:13:57,627
- Yeah, about
three times faster
354
00:13:57,712 --> 00:13:58,920
than he did the first round.
355
00:13:59,005 --> 00:14:01,172
- Not bad for 40 minutes.
356
00:14:01,258 --> 00:14:03,967
- Jimmy's blade is so thin he's
bending it with the wire brush
357
00:14:04,052 --> 00:14:05,009
as he's cleaning
the scale off.
358
00:14:05,095 --> 00:14:06,636
- Oh, my goodness.
359
00:14:06,721 --> 00:14:08,179
Jimmy's doing the exact
same thing he did last time.
360
00:14:08,265 --> 00:14:09,264
- Exactly the same.
361
00:14:09,349 --> 00:14:11,140
- I'm ready for the quench.
362
00:14:11,226 --> 00:14:13,184
I'm hoping that it works.
363
00:14:13,228 --> 00:14:16,354
I just don't have enough time
to start a third billet.
364
00:14:16,439 --> 00:14:18,565
- Go, go, go, there we are!
- There we go, number two!
365
00:14:18,650 --> 00:14:20,108
- Jimmy's quenched.
366
00:14:20,193 --> 00:14:21,901
- As it's starting
to cool down a little more,
367
00:14:21,987 --> 00:14:23,862
the back end is starting
to warp a little bit,
368
00:14:23,905 --> 00:14:25,154
so I clamp it up
369
00:14:25,240 --> 00:14:29,284
and give it the slightest
amount of pressure.
370
00:14:29,369 --> 00:14:30,702
- Ah!
- And he just snapped it!
371
00:14:30,745 --> 00:14:33,788
It happened!
- Oh man!
372
00:14:33,874 --> 00:14:36,165
Damn it!
- Get to the welder, man!
373
00:14:36,251 --> 00:14:37,500
Get to the welder.
374
00:14:37,586 --> 00:14:39,544
- I don't have enough time
to start over,
375
00:14:39,629 --> 00:14:42,130
but I'm going to do everything
I can to make a blade.
376
00:14:42,215 --> 00:14:43,882
I don't even wait
for it to cool off.
377
00:14:43,967 --> 00:14:45,508
I'm a welding instructor.
378
00:14:45,594 --> 00:14:48,261
I figure I might as well do
what I'm good at.
379
00:14:48,346 --> 00:14:50,054
- Man, I feel for jimmy.
380
00:14:50,140 --> 00:14:53,725
This is so brutal!
381
00:14:53,810 --> 00:14:57,437
- I add a layer of clay
to the spine in hopes
382
00:14:57,522 --> 00:15:00,106
that it will keep
the spine nice and soft
383
00:15:00,191 --> 00:15:03,234
so when they're doing
any chopping challenges,
384
00:15:03,320 --> 00:15:05,236
it'll be more
resistant to shock.
385
00:15:05,280 --> 00:15:08,031
Fingers crossed,
the quench should go well.
386
00:15:08,116 --> 00:15:11,701
♪ ♪
387
00:15:11,786 --> 00:15:13,786
- eric's giving it
a good file check.
388
00:15:13,872 --> 00:15:15,038
The moment of truth!
389
00:15:15,123 --> 00:15:16,539
♪ ♪
390
00:15:16,625 --> 00:15:17,874
- nice!
391
00:15:17,918 --> 00:15:21,252
I am successful.
392
00:15:21,296 --> 00:15:23,546
- So I know time
is running out.
393
00:15:23,632 --> 00:15:25,089
I'm going to edge quench it.
394
00:15:25,175 --> 00:15:26,966
- Whoa, whoa, whoa!
- Holy smokes!
395
00:15:27,052 --> 00:15:28,593
- That was a hot blade.
396
00:15:28,678 --> 00:15:32,096
- This is where you worry
about hearing that tink!
397
00:15:32,182 --> 00:15:33,348
[soft ping]
- oh!
398
00:15:33,433 --> 00:15:36,267
- And there it happened.
399
00:15:36,311 --> 00:15:37,644
My heart drops.
400
00:15:37,729 --> 00:15:40,104
I notice that there's
a crack on the blade.
401
00:15:40,190 --> 00:15:41,648
- It's not that surprising.
402
00:15:41,733 --> 00:15:43,650
Martin quenched
at a very high temperatur.
403
00:15:43,735 --> 00:15:45,151
- Do you think
if there's one crack,
404
00:15:45,236 --> 00:15:47,612
there's going to be more?
- Usually.
405
00:15:47,697 --> 00:15:49,781
- I ain't got it in me
to do anything else.
406
00:15:49,824 --> 00:15:52,825
- I think martin's
tapping out.
407
00:15:52,911 --> 00:15:54,243
- I feel like it's an issue
408
00:15:54,329 --> 00:15:56,537
that I know I can
potentially fix later.
409
00:15:56,623 --> 00:15:59,415
I have something to turn
into the judges at this poin,
410
00:15:59,501 --> 00:16:01,292
and I don't want to press
my luck any further.
411
00:16:01,378 --> 00:16:03,628
- Well, he's got a quenched
and hardened blade,
412
00:16:03,713 --> 00:16:05,880
so as long as
he's within parameters,
413
00:16:05,966 --> 00:16:07,548
he's still in the running.
414
00:16:07,634 --> 00:16:12,178
- Five, four,
three, two, one!
415
00:16:12,263 --> 00:16:14,097
Gentlemen,
round one is over!
416
00:16:14,182 --> 00:16:15,765
♪ ♪
417
00:16:15,850 --> 00:16:17,558
- even though the blade
broke in half,
418
00:16:17,644 --> 00:16:19,519
the welds came out all right,
419
00:16:19,604 --> 00:16:22,105
so I'm thinking
I might have this.
420
00:16:22,190 --> 00:16:23,773
I've seen people
come back from worse.
421
00:16:23,858 --> 00:16:27,485
♪ ♪
422
00:16:27,570 --> 00:16:29,696
- gentlemen, in the first three
hours of this competition,
423
00:16:29,781 --> 00:16:32,657
we asked you to recreate
boyd ritters' hwando sword
424
00:16:32,742 --> 00:16:34,409
and then do something
we've never
425
00:16:34,494 --> 00:16:36,536
asked smiths to do before:
A water quench.
426
00:16:36,621 --> 00:16:38,454
And you all have blades
to turn in,
427
00:16:38,498 --> 00:16:40,665
so every one of you
has something to be proud of,
428
00:16:40,709 --> 00:16:42,166
but this is a competition,
429
00:16:42,252 --> 00:16:44,085
which means there have
to be eliminations.
430
00:16:44,170 --> 00:16:45,962
Time has come
for our first critique,
431
00:16:46,006 --> 00:16:48,464
and eric, you're up first.
Please present your work.
432
00:16:48,550 --> 00:16:50,967
♪ ♪
433
00:16:51,052 --> 00:16:53,720
- eric, right off the bat,
looking at this,
434
00:16:53,805 --> 00:16:55,221
the steel looks really good.
435
00:16:55,306 --> 00:16:57,306
You did all the prep work
that I like seeing
436
00:16:57,392 --> 00:16:59,350
to get that grain
structure down tight,
437
00:16:59,394 --> 00:17:01,394
so you have fewer problems
in the quench.
438
00:17:01,479 --> 00:17:03,312
Right now, you don't have
clearly-defined shoulders
439
00:17:03,398 --> 00:17:04,897
on the spine of this blade,
440
00:17:04,983 --> 00:17:07,108
so if you move forward,
the biggest thing I see
441
00:17:07,193 --> 00:17:09,527
is how you're going to set up
for the habaki,
442
00:17:09,612 --> 00:17:11,070
the guard, handle,
and all that,
443
00:17:11,156 --> 00:17:13,197
but other than that,
well on your way.
444
00:17:13,283 --> 00:17:14,532
Nicely done.
- Thank you.
445
00:17:14,617 --> 00:17:15,825
- Dave, you're up next.
You ready?
446
00:17:15,910 --> 00:17:17,827
- Yes, sir.
- Please present your work.
447
00:17:17,912 --> 00:17:20,038
♪ ♪
448
00:17:20,081 --> 00:17:22,331
- dave, you do have
a couple issues.
449
00:17:22,417 --> 00:17:24,542
You do have a couple of cracks
right on the edge,
450
00:17:24,586 --> 00:17:26,878
and they kind of come up
and curve back.
451
00:17:26,963 --> 00:17:28,713
So if you move
onto the next round,
452
00:17:28,798 --> 00:17:30,214
I'd address those,
453
00:17:30,258 --> 00:17:32,341
so this thing
doesn't come flying apart,
454
00:17:32,427 --> 00:17:35,344
but the rest of the blade
looks pretty solid,
455
00:17:35,430 --> 00:17:37,388
and you left yourself
some good sacrificial material
456
00:17:37,474 --> 00:17:38,723
to deal with,
so good job on that.
457
00:17:38,808 --> 00:17:40,725
- Thank you.
458
00:17:40,810 --> 00:17:42,143
- Martin, how you feeling?
- I'm feeling okay.
459
00:17:42,228 --> 00:17:44,520
Thank you.
- Please present your work.
460
00:17:44,606 --> 00:17:46,147
♪ ♪
461
00:17:46,232 --> 00:17:48,316
- the profile you have here
isn't bad at all,
462
00:17:48,401 --> 00:17:50,943
but your knife has
a little bit of a warp,
463
00:17:51,029 --> 00:17:52,528
as you can see, sir.
464
00:17:52,572 --> 00:17:55,740
But the really big thing
that I see with your weapon
465
00:17:55,825 --> 00:17:58,910
right here is that you have
two visible cracks.
466
00:17:58,953 --> 00:18:02,038
One goes right across
the edge,
467
00:18:02,123 --> 00:18:04,332
but this one down here
actually is open,
468
00:18:04,417 --> 00:18:06,167
where I can see
right through that.
469
00:18:06,252 --> 00:18:08,211
You definitely have
to take care of that.
470
00:18:08,296 --> 00:18:10,463
♪ ♪
471
00:18:10,548 --> 00:18:12,256
- jimmy, you ready?
- I am.
472
00:18:12,342 --> 00:18:14,550
- Please present your work.
473
00:18:14,636 --> 00:18:16,427
♪ ♪
474
00:18:16,513 --> 00:18:18,721
- jimmy, you did something
that I really like to see,
475
00:18:18,807 --> 00:18:21,140
which was testing the materil
and in testing the material,
476
00:18:21,226 --> 00:18:22,767
you found out
it was pretty brittle.
477
00:18:22,852 --> 00:18:25,520
So after coming out of that
quench, all I was thinking is,
478
00:18:25,605 --> 00:18:27,313
"ah, we're going to
see that again,"
479
00:18:27,398 --> 00:18:29,065
and we did.
480
00:18:29,150 --> 00:18:31,109
There are multiple cracks
along this edge
481
00:18:31,194 --> 00:18:32,485
that are very small,
482
00:18:32,570 --> 00:18:34,362
and any one of those
can be the stress riser
483
00:18:34,447 --> 00:18:35,822
that breaks these blades.
484
00:18:35,907 --> 00:18:37,824
But you got a good shape
going there.
485
00:18:37,909 --> 00:18:39,408
You never gave up.
Good job.
486
00:18:39,494 --> 00:18:41,911
- Thank you, sir.
487
00:18:41,996 --> 00:18:44,288
- Gentlemen, we gave you
a very difficult task
488
00:18:44,374 --> 00:18:45,873
in the first round
of this competition.
489
00:18:45,959 --> 00:18:47,625
You should all be proud
of yourselves,
490
00:18:47,710 --> 00:18:49,418
but only three of you
can move forward.
491
00:18:49,504 --> 00:18:50,878
The judges have
made their decision,
492
00:18:50,964 --> 00:18:52,755
and the bladesmith
leaving the forge...
493
00:18:52,841 --> 00:18:55,299
♪ ♪
494
00:18:55,385 --> 00:18:57,635
is martin.
495
00:18:57,720 --> 00:19:00,388
- Martin, you've developed
a warp and an extreme curve
496
00:19:00,473 --> 00:19:02,807
in that blade that actually
peeled your steel apart,
497
00:19:02,892 --> 00:19:04,475
and you've got
wide-open cracks.
498
00:19:04,519 --> 00:19:05,643
That's why we're
letting you go.
499
00:19:05,687 --> 00:19:06,853
- I understand.
500
00:19:06,938 --> 00:19:08,896
- Martin, you fought hard,
but unfortunately,
501
00:19:08,982 --> 00:19:10,648
I'm going to have to ask you
to please surrender your work
502
00:19:10,733 --> 00:19:12,859
and leave the forge.
503
00:19:12,944 --> 00:19:14,777
- The competition
is very tough.
504
00:19:14,863 --> 00:19:16,279
It is definitely no joke,
505
00:19:16,364 --> 00:19:18,990
but I had so much fun,
I can't even tell you.
506
00:19:19,075 --> 00:19:20,408
I feel like
I have to go home
507
00:19:20,493 --> 00:19:22,285
and try the water quench
from the house.
508
00:19:22,370 --> 00:19:25,830
♪ ♪
509
00:19:25,874 --> 00:19:27,206
- well, gentlemen,
congratulations.
510
00:19:27,292 --> 00:19:28,583
The three of you have made it
511
00:19:28,668 --> 00:19:30,168
through into the second round
of our competition,
512
00:19:30,253 --> 00:19:31,502
where you're going
to fix any issues
513
00:19:31,588 --> 00:19:33,713
you have with your blades
and add handles to them,
514
00:19:33,798 --> 00:19:36,048
turning them into fully
functioning weapons.
515
00:19:36,134 --> 00:19:40,178
Now, we asked you to recreate
boyd ritters' hwando swor.
516
00:19:40,263 --> 00:19:43,264
So, in this round,
your handles are no different.
517
00:19:43,349 --> 00:19:46,225
You need to include a habaki,
a guard, a wrap-handle
518
00:19:46,311 --> 00:19:48,644
and, at the end of this round,
the judges are going to test
519
00:19:48,730 --> 00:19:51,564
for strength and durability
in a wax wood staff attac,
520
00:19:51,649 --> 00:19:52,899
and we're going to check
for edge retention
521
00:19:52,984 --> 00:19:55,026
in a rubber tube slice.
522
00:19:55,111 --> 00:19:57,862
You guys have two hours on
the clock to complete all that.
523
00:19:57,906 --> 00:20:00,656
Good luck.
Your time starts now.
524
00:20:00,742 --> 00:20:01,824
♪ ♪
525
00:20:01,910 --> 00:20:03,576
- all right,
so we've got cracks.
526
00:20:03,661 --> 00:20:06,078
- Dave has some serious
cracking issues
527
00:20:06,164 --> 00:20:08,164
that he's got to clear up.
- Yeah.
528
00:20:08,249 --> 00:20:09,624
♪ ♪
529
00:20:09,709 --> 00:20:11,709
- a crack on the edge
is a death sentence to knife
530
00:20:11,794 --> 00:20:14,587
because as soon as you hit it,
it's gone, it's two pieces.
531
00:20:14,672 --> 00:20:18,049
What I'm doing is opening up
deeper surface area
532
00:20:18,092 --> 00:20:19,634
so that I can fill
in those welds
533
00:20:19,719 --> 00:20:21,886
and then grind it off
as I shape the edge.
534
00:20:21,971 --> 00:20:25,389
- The key question is, are
they able to fix those cracks
535
00:20:25,475 --> 00:20:27,308
and really support it?
536
00:20:27,393 --> 00:20:30,645
- That's ugly,
but it's fixed, temporarily.
537
00:20:30,730 --> 00:20:35,733
- Jimmy over here had a blade
that broke in half, was welded.
538
00:20:35,818 --> 00:20:38,361
- It's also got multiple cracks
along the edge.
539
00:20:38,404 --> 00:20:40,905
- I've got a bunch of cracks
to take care of,
540
00:20:40,990 --> 00:20:43,282
so I start opening
the biggest ones possible
541
00:20:43,368 --> 00:20:45,076
so I can weld them together.
542
00:20:45,161 --> 00:20:47,036
My biggest concern
in this round
543
00:20:47,121 --> 00:20:51,040
is not getting all
the cracks welded up.
544
00:20:51,084 --> 00:20:53,292
Now that I've got
the spine welded up,
545
00:20:53,378 --> 00:20:54,794
I've got my edge welded up.
546
00:20:54,879 --> 00:20:56,420
All I can do is hope
547
00:20:56,506 --> 00:20:59,048
that my blade survives
that strength test.
548
00:20:59,133 --> 00:21:02,093
Man, that's ugly!
549
00:21:02,136 --> 00:21:03,803
- Dave mentioned
he has concerns
550
00:21:03,888 --> 00:21:05,388
about how my habaki's
going to fit up,
551
00:21:05,473 --> 00:21:07,473
so I need to grind
a shoulder on the top
552
00:21:07,558 --> 00:21:09,517
and match the angle
on the bottom.
553
00:21:09,602 --> 00:21:12,103
The habaki,
when you put it on the blade,
554
00:21:12,188 --> 00:21:15,231
should be somewhat tight,
so just getting it fit up
555
00:21:15,316 --> 00:21:17,900
and hoping
that it's a tight fit.
556
00:21:17,986 --> 00:21:19,402
- Eric's fitting up
his habaki,
557
00:21:19,487 --> 00:21:20,820
and it looks pretty tight.
558
00:21:20,905 --> 00:21:23,906
♪ ♪
559
00:21:23,992 --> 00:21:25,324
- after I get my guard fitted,
560
00:21:25,410 --> 00:21:27,451
I grab three pieces
of green g-10.
561
00:21:27,537 --> 00:21:30,579
- Dave looks like he's actually
making a frame handle.
562
00:21:30,665 --> 00:21:32,540
- I'm cutting the middle piee
of g-10
563
00:21:32,625 --> 00:21:33,916
to fit around the tang,
564
00:21:34,002 --> 00:21:35,918
and then I'm going to put
a piece of g-10
565
00:21:36,004 --> 00:21:38,087
on either side of it,
secure it with a pin,
566
00:21:38,172 --> 00:21:39,297
and that's what's going to hold
everything in place.
567
00:21:39,340 --> 00:21:41,007
This is the quickest way
568
00:21:41,092 --> 00:21:42,341
I could think of
to do a handle.
569
00:21:42,427 --> 00:21:45,469
Okay, cord, cord, cord, cord.
570
00:21:45,555 --> 00:21:48,431
- All right, guys.
You have one hour remaining.
571
00:21:48,516 --> 00:21:49,974
- Thank you, sir!
572
00:21:50,018 --> 00:21:53,352
I've got my scales
ready to go,
573
00:21:53,438 --> 00:21:56,147
and my guard and habaki
are all fitted up,
574
00:21:56,232 --> 00:21:57,773
and I'm starting
to feel pretty good.
575
00:21:57,859 --> 00:22:00,985
It's a shame to cover up
this nice chunk of wood.
576
00:22:01,029 --> 00:22:02,987
- All right.
Jimmy is starting his wrap.
577
00:22:03,072 --> 00:22:05,531
- I don't have a lot of time
to spend on it,
578
00:22:05,616 --> 00:22:08,326
so I'm choosing
the easiest way
579
00:22:08,411 --> 00:22:10,828
to wrap it as tight as I can
in a spiral fashion.
580
00:22:12,457 --> 00:22:14,165
- So now that I've got
the handle material
581
00:22:14,208 --> 00:22:15,666
wrapped and tucked in,
582
00:22:15,752 --> 00:22:18,294
the last thing I have to do
is get this pommel on there,
583
00:22:18,379 --> 00:22:19,837
get the tang peened over.
584
00:22:19,922 --> 00:22:21,797
Ideally,
for a peening over a tan,
585
00:22:21,883 --> 00:22:24,717
you would add some heat,
but with the paracord
586
00:22:24,802 --> 00:22:27,678
and the handle material
3/8ths of an inch away,
587
00:22:27,722 --> 00:22:30,181
and I don't feel comfortable
adding heat.
588
00:22:31,476 --> 00:22:33,225
- Ooh! It didn't work.
589
00:22:33,311 --> 00:22:35,853
- Getting this tang
peened over
590
00:22:35,938 --> 00:22:38,564
is taking me a lot longer
than I would like to.
591
00:22:38,649 --> 00:22:40,775
My arm's starting
to get tired.
592
00:22:40,860 --> 00:22:42,485
- I think what's happening
is he tried to peen over t
593
00:22:42,570 --> 00:22:44,904
with too much material,
so you're really not moving
594
00:22:44,989 --> 00:22:47,323
the material
the way you want it to.
595
00:22:47,408 --> 00:22:49,867
- I'm stuck using
the peen of my hammer
596
00:22:49,911 --> 00:22:51,327
to spread this material,
597
00:22:51,412 --> 00:22:53,371
and it's just not going
as quickly as I would like.
598
00:22:53,414 --> 00:22:56,665
I don't think there would be
any saving my handle
599
00:22:56,751 --> 00:22:58,626
if I can't make this work.
600
00:22:58,711 --> 00:23:05,049
Oh, my goodness.
601
00:23:05,093 --> 00:23:06,550
- Well, right now, eric
has to solve the problem
602
00:23:06,594 --> 00:23:09,053
in his butt cap.
It still looks very loose.
603
00:23:09,097 --> 00:23:11,222
- Thankfully,
I finally get it secured.
604
00:23:11,265 --> 00:23:13,516
There's about 20 minutes
left in the competition,
605
00:23:13,559 --> 00:23:15,017
and I just got to make sure
606
00:23:15,103 --> 00:23:16,685
that my blade
is nice and sharp
607
00:23:16,771 --> 00:23:19,647
and it's going to cut anything
that they throw at it.
608
00:23:19,732 --> 00:23:23,484
♪ ♪
609
00:23:23,569 --> 00:23:25,653
- with this knife,
I'm going to try to do
610
00:23:25,738 --> 00:23:29,323
a pretty blunt convexed edge.
611
00:23:29,409 --> 00:23:30,866
It's going to be sharp
but not that sharp,
612
00:23:30,952 --> 00:23:32,868
so it will have
a little bit more insurance
613
00:23:32,954 --> 00:23:33,911
against it breaking.
614
00:23:33,955 --> 00:23:36,163
We'll see what happens.
615
00:23:36,249 --> 00:23:38,791
♪ ♪
616
00:23:38,876 --> 00:23:40,668
- aw!
617
00:23:40,753 --> 00:23:42,169
- What?
618
00:23:42,255 --> 00:23:45,923
- As I grind on it, I'm seeing
more and more cracks.
619
00:23:45,967 --> 00:23:47,800
- Oh, hell!
620
00:23:47,885 --> 00:23:49,552
- Because of how thin
the blade is,
621
00:23:49,637 --> 00:23:52,096
it's a little more delicate
than I would hope it to be.
622
00:23:52,140 --> 00:23:53,597
There's nothing else I can do.
623
00:23:53,641 --> 00:23:55,891
I'm hoping
that it holds together.
624
00:23:55,977 --> 00:23:57,935
♪ ♪
625
00:23:58,020 --> 00:24:00,312
- five, four,
626
00:24:00,398 --> 00:24:02,189
three, two,
627
00:24:02,275 --> 00:24:05,734
one.
Gentlemen, round two is over!
628
00:24:06,696 --> 00:24:10,197
- I'm overall happy
with how I did.
629
00:24:10,283 --> 00:24:11,657
The handle is not
my best work,
630
00:24:11,742 --> 00:24:15,744
but it does feel comfortable
in the hand, so I'm happy.
631
00:24:15,830 --> 00:24:19,540
♪ ♪
632
00:24:19,625 --> 00:24:22,334
- bladesmiths,
welcome to our strength test.
633
00:24:22,420 --> 00:24:25,463
The wax wood staff attack--
634
00:24:25,548 --> 00:24:28,716
that's going to test
how your heat treat worked out
635
00:24:28,801 --> 00:24:30,342
and the overall construction
of your weapons.
636
00:24:30,428 --> 00:24:31,635
Sound like fun?
637
00:24:31,721 --> 00:24:33,053
- Let's do it.
- Yeah!
638
00:24:33,139 --> 00:24:35,181
- Such enthusiasm.
639
00:24:35,266 --> 00:24:36,724
Eric, you're first.
Are you ready to go?
640
00:24:36,809 --> 00:24:39,059
- Let's see what she's got.
- All right. Let's do it.
641
00:24:40,480 --> 00:24:43,022
- Water quench
is a very vigorous
642
00:24:43,107 --> 00:24:45,733
and very aggressive quench.
643
00:24:45,818 --> 00:24:48,235
This could definitely snap
my blade right in half.
644
00:24:48,321 --> 00:24:51,739
[rock music]
645
00:24:51,824 --> 00:24:52,114
♪ ♪
646
00:24:56,287 --> 00:25:02,500
♪ ♪
647
00:25:09,800 --> 00:25:12,760
- all right, eric.
You survived. Nice job.
648
00:25:12,845 --> 00:25:14,637
You did pick up a bend,
649
00:25:14,722 --> 00:25:17,598
but you have no damage
to your edge whatsoever.
650
00:25:17,683 --> 00:25:19,350
Proof of concept
that a water quench
651
00:25:19,435 --> 00:25:22,520
is a viable method,
so good job.
652
00:25:22,563 --> 00:25:23,979
- Thank you.
- Dave, you're up next.
653
00:25:24,065 --> 00:25:25,814
You ready?
- No.
654
00:25:25,900 --> 00:25:27,316
- Well, we're gonna do it
anyway.
655
00:25:27,401 --> 00:25:28,484
- Okay.
656
00:25:28,528 --> 00:25:31,111
After watching eric's blade
657
00:25:31,197 --> 00:25:33,989
just get beat on
under those staffs,
658
00:25:34,075 --> 00:25:37,201
all I can think of is jay
is about to go full neilson.
659
00:25:37,245 --> 00:25:39,328
This is not going to be pretty.
660
00:25:39,372 --> 00:25:42,331
[rock music]
661
00:25:42,416 --> 00:25:44,959
♪ ♪
662
00:25:45,044 --> 00:25:46,502
damn!
663
00:25:53,427 --> 00:25:56,387
- Oops.
- Yeah.
664
00:25:56,430 --> 00:25:58,222
- Actually, don't feel bad
about this.
665
00:25:58,266 --> 00:26:00,099
Your grain structure
is actually not bad.
666
00:26:00,184 --> 00:26:01,725
It's slightly coarse.
667
00:26:01,811 --> 00:26:04,520
It's not quite that gray
velvet you want,
668
00:26:04,605 --> 00:26:06,230
but once I hit it,
669
00:26:06,274 --> 00:26:11,068
the shock traveled
into this fracture right here.
670
00:26:11,153 --> 00:26:14,905
But your overall construction,
everything is tight.
671
00:26:14,949 --> 00:26:17,700
You turned in something viable,
672
00:26:17,785 --> 00:26:19,159
just didn't make it
through this test.
673
00:26:19,245 --> 00:26:21,078
- Yep.
674
00:26:23,249 --> 00:26:24,623
- Hate to see it, dave,
675
00:26:24,709 --> 00:26:26,542
but you did suffer
a catastrophic failure
676
00:26:26,627 --> 00:26:29,837
during the first swing
on the wax wood staff,
677
00:26:29,922 --> 00:26:32,298
but you're not out
of the fight yet.
678
00:26:32,383 --> 00:26:34,758
Now, jimmy,
you have to survive
679
00:26:34,844 --> 00:26:36,927
one strike
on the wax wood staff
680
00:26:37,013 --> 00:26:38,887
to move forward
in this competition. You ready?
681
00:26:38,973 --> 00:26:41,432
- I am ready.
- All right. Let's do it. Jay?
682
00:26:43,603 --> 00:26:45,769
- I am feeling
so much pressure.
683
00:26:45,813 --> 00:26:47,730
This is literally
a make-or-break moment,
684
00:26:47,815 --> 00:26:51,191
and I'm just hoping
and praying.
685
00:26:51,277 --> 00:26:54,403
[suspenseful music]
686
00:26:54,488 --> 00:27:01,619
♪ ♪
687
00:27:03,956 --> 00:27:04,955
- [bleep]
688
00:27:12,632 --> 00:27:16,550
- jimmy,
we got several pieces,
689
00:27:16,636 --> 00:27:20,095
and you can see on each one
there's dark spots.
690
00:27:20,181 --> 00:27:22,139
There were cracks in the blade.
691
00:27:22,183 --> 00:27:23,641
- Damn.
692
00:27:23,684 --> 00:27:26,977
- The grain structure is
really, really big, but, again,
693
00:27:27,063 --> 00:27:30,147
water quench--you fought hard.
694
00:27:30,232 --> 00:27:33,484
You've got to be proud of that.
- Thank you, sir.
695
00:27:35,571 --> 00:27:38,113
- Eric, you are moving forward
into the third round,
696
00:27:38,199 --> 00:27:39,615
so congratulations.
697
00:27:39,659 --> 00:27:42,743
Now, gentlemen, it came down
to two broken blades,
698
00:27:42,828 --> 00:27:43,952
but only one of you guys
699
00:27:44,038 --> 00:27:46,413
is moving forward
in this competition,
700
00:27:46,499 --> 00:27:50,084
and the bladesmith
leaving the forge is...
701
00:27:50,169 --> 00:27:52,961
Jimmy.
702
00:27:53,047 --> 00:27:55,130
- Jimmy, first off,
I commend you for that wok
703
00:27:55,216 --> 00:27:57,841
you did in the first round.
You did not give up at all.
704
00:27:57,927 --> 00:27:59,593
That's something
to be proud of.
705
00:27:59,679 --> 00:28:02,096
When it came to this break,
it was one blade
706
00:28:02,181 --> 00:28:06,183
broke in one spot.
Your blade literally shattered,
707
00:28:06,227 --> 00:28:08,185
and there's no longer
a viable blade there,
708
00:28:08,229 --> 00:28:09,645
and that's why
we're letting you go.
709
00:28:09,730 --> 00:28:11,480
- I understand.
- Well, jimmy, unfortunately,
710
00:28:11,565 --> 00:28:13,607
you're not going to be moving
forward in this competition,
711
00:28:13,693 --> 00:28:14,900
and I'm going to
have to ask you
712
00:28:14,985 --> 00:28:16,151
to please step off
the forge floor, man.
713
00:28:16,237 --> 00:28:17,695
- Thank you, all.
It's been an honor.
714
00:28:17,780 --> 00:28:19,363
I was hoping
to survive one strike,
715
00:28:19,448 --> 00:28:21,824
but unfortunately not.
716
00:28:21,909 --> 00:28:24,076
Even though I didn't win,
717
00:28:24,161 --> 00:28:28,038
I know that I am
a damn good smith,
718
00:28:28,082 --> 00:28:32,000
and I can make
a blade worth wielding.
719
00:28:32,086 --> 00:28:34,503
♪ ♪
720
00:28:34,547 --> 00:28:35,879
- eric, dave, congratulations.
721
00:28:35,965 --> 00:28:38,215
Gentlemen, you guys have
solidified yourself spots
722
00:28:38,300 --> 00:28:41,051
in our third and final round
of this competition.
723
00:28:41,137 --> 00:28:42,636
Now, in this final round,
we're going to be
724
00:28:42,722 --> 00:28:44,346
sending you guys back
to your home forges
725
00:28:44,432 --> 00:28:47,057
to build yet another iconic
weapon from korean history.
726
00:28:47,101 --> 00:28:49,184
We're going to have
you build this.
727
00:28:49,270 --> 00:28:52,896
♪ ♪
728
00:28:52,940 --> 00:28:54,857
the woldo.
729
00:28:54,942 --> 00:28:57,276
- The woldo is a polearm
weapon that has been wielded
730
00:28:57,361 --> 00:29:00,320
by korean warriors
since the 6th century.
731
00:29:00,406 --> 00:29:01,780
The large crescent blade
732
00:29:01,866 --> 00:29:03,699
provided the user
with incredible force
733
00:29:03,784 --> 00:29:05,701
that delivered lethal blows
and deep cuts
734
00:29:05,786 --> 00:29:08,036
with one swing
into an opponent.
735
00:29:08,080 --> 00:29:10,956
Historically, this heavy
weapon required special skils
736
00:29:11,041 --> 00:29:14,710
and was only wielded in battle
by elite korean warriors.
737
00:29:14,795 --> 00:29:18,172
Today, korean martial artists
who specialize in the woldo
738
00:29:18,257 --> 00:29:21,258
perform intricate maneuvers
with this intimidating weapon
739
00:29:21,302 --> 00:29:23,719
at festivals
and cultural events.
740
00:29:23,763 --> 00:29:25,637
- Now, guys, your blades
741
00:29:25,723 --> 00:29:28,474
need to measure
between 22 and 24 inches.
742
00:29:28,559 --> 00:29:30,893
You need to feature
a peak on the spine.
743
00:29:30,978 --> 00:29:33,771
You guys also need
to feature a guard
744
00:29:33,814 --> 00:29:36,899
and a 50 to 52-inch polearm.
745
00:29:36,984 --> 00:29:39,401
The good news is the water
quench is behind you,
746
00:29:39,445 --> 00:29:40,903
so you guys can forget
about that.
747
00:29:40,988 --> 00:29:43,155
You can choose to quench
however you want.
748
00:29:43,240 --> 00:29:46,116
- That weapon is big.
749
00:29:46,160 --> 00:29:48,327
I've never finished
a blade this long.
750
00:29:48,412 --> 00:29:52,915
I have made a blade this long,
and it broke upon testing,
751
00:29:53,000 --> 00:29:56,460
so hopefully,
this one will go much better.
752
00:29:56,545 --> 00:29:58,420
- All right, gentlemen,
and we're giving you four days
753
00:29:58,506 --> 00:29:59,588
to build your woldo swords,
754
00:29:59,673 --> 00:30:01,340
and I want to see
your best work,
755
00:30:01,425 --> 00:30:05,093
because one of them
will be worth $10,000.
756
00:30:05,179 --> 00:30:07,763
We'll see you in four days.
757
00:30:07,848 --> 00:30:10,974
♪ ♪
758
00:30:11,060 --> 00:30:12,810
- I'm back here at my home
forge in detroit.
759
00:30:12,853 --> 00:30:14,478
Excited to get the forge
fired up
760
00:30:14,522 --> 00:30:16,980
and start going on this woldo.
Look at that!
761
00:30:17,024 --> 00:30:19,942
This thing's going to be
almost as tall as I am,
762
00:30:19,985 --> 00:30:21,944
and that's pretty frightening.
763
00:30:22,029 --> 00:30:24,571
So I'm to the point
where I've got the blade
764
00:30:24,657 --> 00:30:26,156
forged out.
765
00:30:26,242 --> 00:30:29,743
I have to cut a notch and
use a chisel to open it up.
766
00:30:29,829 --> 00:30:32,454
There we go!
The woldo is in good shape.
767
00:30:32,540 --> 00:30:34,832
I got plenty of meat on there
that I can grind back
768
00:30:34,875 --> 00:30:36,625
and get to the shape
I'm looking for.
769
00:30:36,710 --> 00:30:39,419
♪ ♪
770
00:30:39,505 --> 00:30:41,129
- we're back here in auburn,
illinois.
771
00:30:41,215 --> 00:30:43,340
My goal for the day is to hae
the rough shape forged
772
00:30:43,384 --> 00:30:46,510
and to have a solid piece
when I'm done for the da.
773
00:30:46,595 --> 00:30:48,679
This is a little outside
of my comfort zone.
774
00:30:48,764 --> 00:30:50,389
This has some weird curves
and peaks to it
775
00:30:50,474 --> 00:30:52,349
that's going to be
a bit of a forging challenge.
776
00:30:52,393 --> 00:30:54,434
I may have ruined
this early on.
777
00:30:54,520 --> 00:30:57,312
I forged the piece over
so that actually the top pat
778
00:30:57,398 --> 00:30:58,272
is actually
folding over on itself.
779
00:30:58,357 --> 00:30:59,982
It's called a cold shut.
780
00:31:00,067 --> 00:31:01,316
It causes all kinds
of problems later on
781
00:31:01,402 --> 00:31:02,901
because the pieces
aren't attached.
782
00:31:02,987 --> 00:31:04,903
I go over the grinder.
783
00:31:04,989 --> 00:31:06,989
If I can grind it out,
I'm not too bad,
784
00:31:07,074 --> 00:31:10,492
but if it's really deep
or it's something I can't fix,
785
00:31:10,536 --> 00:31:12,703
I'm screwed.
786
00:31:13,956 --> 00:31:17,207
- Day two, rough brand is done.
So here I am,
787
00:31:17,293 --> 00:31:20,502
a man asking for all
the bladesmiths of the univere
788
00:31:20,588 --> 00:31:22,337
to send me their good juju.
789
00:31:22,381 --> 00:31:25,340
[suspenseful music]
790
00:31:25,426 --> 00:31:32,180
♪ ♪
791
00:31:32,224 --> 00:31:35,058
that is a hard blade.
792
00:31:35,102 --> 00:31:36,852
Overall, good quench.
793
00:31:36,937 --> 00:31:38,228
♪ ♪
794
00:31:38,314 --> 00:31:40,856
- day two today, my goal is
to get the bevels in,
795
00:31:40,941 --> 00:31:42,900
get it ground
and get it heat treated.
796
00:31:42,943 --> 00:31:45,360
I do see one problem.
It's opened up on me.
797
00:31:45,404 --> 00:31:46,695
I've got a real problem.
798
00:31:46,780 --> 00:31:48,405
Apparently, when I ground
that cold shut out,
799
00:31:48,490 --> 00:31:49,823
I didn't get it
completely ground out,
800
00:31:49,909 --> 00:31:50,991
and it folded over
a little bit.
801
00:31:51,076 --> 00:31:53,035
Pfffttt.
802
00:31:53,120 --> 00:31:57,080
If it goes deep into the seal,
man, I'm probably in bad shape.
803
00:31:57,166 --> 00:31:59,207
If it runs all the way through,
then the blade is ruined,
804
00:31:59,293 --> 00:32:00,876
and I've got to start over.
805
00:32:00,961 --> 00:32:03,378
So I'm trying to figure out
what I can do.
806
00:32:03,464 --> 00:32:06,548
Is this something I can repair
or am I just plain old screwed
807
00:32:06,634 --> 00:32:08,175
and it's time to start again?
808
00:32:13,140 --> 00:32:14,932
So right now
it's just back to the grinder.
809
00:32:14,975 --> 00:32:17,017
Good news is
everything's solid.
810
00:32:17,102 --> 00:32:19,019
The cold shut I was worried
about is grinding out.
811
00:32:19,104 --> 00:32:20,979
I have a blade ready
to heat treat.
812
00:32:21,065 --> 00:32:24,024
[tense music]
813
00:32:24,109 --> 00:32:27,194
♪ ♪
814
00:32:27,279 --> 00:32:29,029
I'm straight?
815
00:32:31,075 --> 00:32:32,658
Yep!
And it's hard.
816
00:32:32,743 --> 00:32:34,534
That's as good
as I can hope for right now.
817
00:32:34,620 --> 00:32:35,953
♪ ♪
818
00:32:35,996 --> 00:32:38,872
- day three. So today,
I have to make the shaft
819
00:32:38,958 --> 00:32:40,999
and then
get everything put together.
820
00:32:41,085 --> 00:32:44,044
So I decide, as a little
decorative embellishment,
821
00:32:44,129 --> 00:32:46,046
to add a little grip
to the handle.
822
00:32:46,131 --> 00:32:49,007
I'm going to flute
and inlay some paracord.
823
00:32:49,093 --> 00:32:52,260
I'm using imperial red
and royal blue
824
00:32:52,346 --> 00:32:55,597
to honor the colors
of the korean flag.
825
00:32:55,683 --> 00:32:57,182
Ooh, nice!
826
00:32:57,267 --> 00:33:01,603
I'm looking pretty good going
into day four, so I'm pleased.
827
00:33:02,481 --> 00:33:06,566
- Day four. Yesterday,
I got the blade finished,
828
00:33:06,652 --> 00:33:08,610
and I've got the shaft shaped
and roughed in,
829
00:33:08,696 --> 00:33:12,072
so today it's a lot of fit,
finish, assembly
830
00:33:12,157 --> 00:33:14,074
and just putting
the final touches on my weapon.
831
00:33:14,159 --> 00:33:16,743
So I grab some pink paracord
that I'm going to use
832
00:33:16,829 --> 00:33:18,787
to wrap the areas
between the collars,
833
00:33:18,872 --> 00:33:20,288
and then I have
a pink wood stain
834
00:33:20,374 --> 00:33:22,332
that I'm going to stain
the hickory with.
835
00:33:22,376 --> 00:33:24,084
When I do a knife show,
I always have one knife
836
00:33:24,169 --> 00:33:25,919
on my table
that has a pink handle.
837
00:33:26,005 --> 00:33:27,170
It's not the typical
looking thing,
838
00:33:27,214 --> 00:33:28,296
but I think
it looks kind of neat,
839
00:33:28,340 --> 00:33:30,173
so I'm going to go with it.
840
00:33:30,217 --> 00:33:32,384
I think this is a solid piece.
I think it will test well,
841
00:33:32,469 --> 00:33:34,094
but we're going to see
what happens.
842
00:33:34,179 --> 00:33:37,848
♪ ♪
843
00:33:37,891 --> 00:33:39,558
- gentlemen, welcome back
to the forge.
844
00:33:39,643 --> 00:33:41,476
You guys had four days to work
on your korean woldos,
845
00:33:41,562 --> 00:33:42,853
and they look great,
846
00:33:42,896 --> 00:33:43,895
but we want to hear
about your builds.
847
00:33:43,981 --> 00:33:46,940
Eric, how did it go for you?
848
00:33:47,026 --> 00:33:48,442
- Overall it went really wel.
849
00:33:48,527 --> 00:33:51,862
Made the blade out of
oil-quenched w-1,
850
00:33:51,905 --> 00:33:54,698
mild steel collars,
paracord wrap
851
00:33:54,742 --> 00:33:57,034
and wrought-iron guard
and pommel.
852
00:33:57,077 --> 00:33:59,995
- Fantastic.
Dave, how did your build go?
853
00:34:00,080 --> 00:34:03,498
- It went pretty well.
The blade is 5160.
854
00:34:03,584 --> 00:34:04,875
The handle is hickory
855
00:34:04,918 --> 00:34:07,836
and has copper collars
and a paracord wrap.
856
00:34:07,921 --> 00:34:10,422
- Well, gentlemen, both
your blades look deadly,
857
00:34:10,507 --> 00:34:12,299
but there's only one way
for us to find out
858
00:34:12,384 --> 00:34:13,925
if they function
as well as they look.
859
00:34:14,011 --> 00:34:16,511
We've got a strength test,
a sharpness test,
860
00:34:16,597 --> 00:34:18,638
and up first, the keal.
Doug?
861
00:34:18,724 --> 00:34:22,476
♪ ♪
862
00:34:22,561 --> 00:34:24,978
- bladesmiths...
[speaking foreign language]
863
00:34:25,064 --> 00:34:28,023
and welcome to the keal test.
864
00:34:28,108 --> 00:34:30,150
To find what kind of lethal
damage your weapons will do,
865
00:34:30,235 --> 00:34:32,527
I will take your weapons
and deliver lethal blows
866
00:34:32,613 --> 00:34:34,362
on this ballistics dummy.
867
00:34:34,448 --> 00:34:35,697
Eric, you're first.
You ready for this?
868
00:34:35,783 --> 00:34:38,825
- Yes, sir.
- All right. Let's do this.
869
00:34:38,911 --> 00:34:42,120
- Bones are dense, and they can
do some damage to an edge,
870
00:34:42,206 --> 00:34:46,166
so my heart's racing.
871
00:34:46,251 --> 00:34:49,336
[suspenseful music]
872
00:34:49,421 --> 00:34:56,259
♪ ♪
873
00:35:07,564 --> 00:35:10,899
- all right, eric. Let's talk
about your woldo here.
874
00:35:10,984 --> 00:35:12,442
It is forward heavy.
875
00:35:12,486 --> 00:35:15,237
There's a lot of metal in here,
but it is wieldable.
876
00:35:15,280 --> 00:35:17,739
Now, your edge is sharp.
877
00:35:17,825 --> 00:35:20,450
It penetrates deeply
into this ballistics dummy,
878
00:35:20,536 --> 00:35:22,786
cutting the gel torso
and into the bones.
879
00:35:22,830 --> 00:35:26,623
Overall, sir, your woldo,
it will keal.
880
00:35:26,708 --> 00:35:28,291
- Thank you.
- All right, dave.
881
00:35:28,377 --> 00:35:29,376
Your turn, sir.
Are you ready?
882
00:35:29,461 --> 00:35:31,711
- Yes, sir.
- Let's do this.
883
00:35:31,797 --> 00:35:33,547
♪ ♪
884
00:35:33,632 --> 00:35:35,257
- I'm looking at this
ballistics dummy right now,
885
00:35:35,342 --> 00:35:36,842
and it's a hard test.
886
00:35:36,927 --> 00:35:39,136
If I messed up on this blade,
that dummy's going to show it,
887
00:35:39,179 --> 00:35:42,097
and if it works well,
parts go flying.
888
00:35:42,182 --> 00:35:49,104
♪ ♪
889
00:36:07,624 --> 00:36:09,541
- all right, dave.
So about your woldo here.
890
00:36:09,626 --> 00:36:12,502
It is a little bit heavier
than the other weapon.
891
00:36:12,546 --> 00:36:14,963
Heavier weapons require
a lot of adjustments,
892
00:36:15,048 --> 00:36:17,549
but your edge here is sharp.
893
00:36:17,634 --> 00:36:19,009
With this forward weight,
894
00:36:19,052 --> 00:36:21,219
it cuts deep into
this ballistics dummy
895
00:36:21,305 --> 00:36:25,348
and cuts the bones inside,
but in doing so, sir,
896
00:36:25,434 --> 00:36:27,976
your edge over here did take
a little bit of rolling.
897
00:36:28,020 --> 00:36:32,022
But the other parts are fine,
898
00:36:32,065 --> 00:36:35,525
and overall, sir,
your woldo will keal.
899
00:36:35,569 --> 00:36:37,944
- Thank you.
900
00:36:41,241 --> 00:36:43,867
- All right, gentlemen.
You know what time it is.
901
00:36:43,952 --> 00:36:45,327
It's time
for the strength test.
902
00:36:45,412 --> 00:36:48,830
We're calling this one
the bamboo man attack.
903
00:36:48,916 --> 00:36:51,458
To test the overall
construction of your blade,
904
00:36:51,543 --> 00:36:54,002
I'm going to take them
and gently tap them against
905
00:36:54,087 --> 00:36:58,298
our bamboo men over here.
And remember, this is not about
906
00:36:58,383 --> 00:36:59,925
what your weapons do
to these targets.
907
00:37:00,010 --> 00:37:01,801
It's about what these targets
do to your weapons.
908
00:37:01,887 --> 00:37:03,094
Eric, you're up first.
Are you ready?
909
00:37:03,180 --> 00:37:05,305
- Yes, sir.
- All right.
910
00:37:05,390 --> 00:37:06,973
- Bamboo's a very hard wood,
911
00:37:07,059 --> 00:37:10,268
and it can definitely take
some chips out of an edge.
912
00:37:10,354 --> 00:37:12,479
And also, with this long
of a handle on it,
913
00:37:12,564 --> 00:37:15,649
it could just snap it in two.
914
00:37:15,734 --> 00:37:18,735
[tense music]
915
00:37:23,075 --> 00:37:27,827
♪ ♪
916
00:37:43,428 --> 00:37:46,513
- so, eric, right off,
this is a heavy beast.
917
00:37:46,598 --> 00:37:48,098
Your balance point is not bad.
918
00:37:48,183 --> 00:37:50,058
I kind of like that
right there,
919
00:37:50,143 --> 00:37:52,018
where you can
manipulate the weapon.
920
00:37:52,104 --> 00:37:54,729
As far as the weapon
performance goes,
921
00:37:54,815 --> 00:37:56,439
you maintained an edge
all the way along.
922
00:37:56,483 --> 00:37:58,566
It's still sharp.
Nicely done.
923
00:37:58,610 --> 00:38:01,278
- Thank you.
- All right, dave. You're up.
924
00:38:01,363 --> 00:38:02,445
You ready?
- Yes, sir.
925
00:38:09,413 --> 00:38:12,539
[dynamic music]
926
00:38:12,624 --> 00:38:19,421
♪ ♪
927
00:38:29,308 --> 00:38:30,765
- all right, dave.
928
00:38:30,851 --> 00:38:34,060
Your weapon is really,
really heavy.
929
00:38:34,146 --> 00:38:37,355
So you can make
a devastating cut,
930
00:38:37,441 --> 00:38:40,275
but recovery is really slow.
931
00:38:40,360 --> 00:38:47,198
As far as the blade, the blade
itself is dented sideways here
932
00:38:47,284 --> 00:38:51,411
and up above here,
but still solid,
933
00:38:51,496 --> 00:38:54,039
so you survived quite nicely.
Well done, dave.
934
00:38:54,124 --> 00:38:55,415
- Thank you.
935
00:38:55,500 --> 00:38:58,209
♪ ♪
936
00:38:58,295 --> 00:39:00,670
- bladesmiths,
this is the sharpness test,
937
00:39:00,714 --> 00:39:03,340
the sugarcane slice.
938
00:39:03,383 --> 00:39:05,091
To find out how sharp
your weapons are,
939
00:39:05,177 --> 00:39:07,385
I'm going to attempt to cut
through all these sugarcanes.
940
00:39:07,471 --> 00:39:09,304
Unlike the strength test,
941
00:39:09,389 --> 00:39:10,597
this is all about
what your weapons do
942
00:39:10,682 --> 00:39:13,016
and how well
they cut the sugarcanes.
943
00:39:13,101 --> 00:39:15,226
Eric,
are you ready to do this?
944
00:39:15,312 --> 00:39:16,269
- Yes, sir.
945
00:39:16,355 --> 00:39:22,525
♪ ♪
946
00:39:35,040 --> 00:39:36,206
- all right, eric.
947
00:39:36,291 --> 00:39:38,124
Let's talk about
your edge here.
948
00:39:38,210 --> 00:39:39,959
Your edge, it's sharp.
949
00:39:40,045 --> 00:39:41,211
It cut through
all the sugarcanes,
950
00:39:41,254 --> 00:39:44,422
and overall, sir,
your weapon will cut.
951
00:39:44,508 --> 00:39:47,092
- Thank you.
- Dave, it's your turn, sir.
952
00:39:47,177 --> 00:39:48,635
You ready for this?
- Yes, sir.
953
00:39:48,720 --> 00:39:56,393
♪ ♪
954
00:40:04,736 --> 00:40:06,653
- damn.
955
00:40:13,745 --> 00:40:16,037
- All right, dave. Let's talk
about your weapon here.
956
00:40:16,123 --> 00:40:20,083
It's still sharp, and it cuts
cleanly all the way through,
957
00:40:20,168 --> 00:40:23,378
but the weight of your blade as
I'm cutting dragged downward,
958
00:40:23,463 --> 00:40:24,963
and I ran out of sugarcane,
959
00:40:25,048 --> 00:40:27,465
but overall, sir, your weapon,
it will cut.
960
00:40:27,551 --> 00:40:28,550
- Thank you.
961
00:40:31,513 --> 00:40:33,263
- Well, gentlemen, you both
performed extremely well
962
00:40:33,348 --> 00:40:34,889
in our korean-themed
challenge.
963
00:40:34,975 --> 00:40:37,725
Both your woldos
did great during our test,
964
00:40:37,811 --> 00:40:40,770
but this is a competition,
and there has to be a winner.
965
00:40:40,856 --> 00:40:42,647
The judges have made
the decision,
966
00:40:42,732 --> 00:40:45,024
and today's "forged in fire"
champion is...
967
00:40:45,110 --> 00:40:48,403
♪ ♪
968
00:40:48,488 --> 00:40:51,322
eric.
Congratulations.
969
00:40:51,408 --> 00:40:52,866
Now, dave, you fought hard,
970
00:40:52,951 --> 00:40:54,451
but unfortunately,
you're not today's winner,
971
00:40:54,494 --> 00:40:57,036
and dave's going
to tell you why.
972
00:40:57,122 --> 00:40:58,705
- Dave, your blade did great
in the kill test,
973
00:40:58,790 --> 00:41:00,832
and it did well
in the sharpness test.
974
00:41:00,917 --> 00:41:02,959
What this came down
to were two things:
975
00:41:03,044 --> 00:41:04,377
The overall weight
of your blade
976
00:41:04,463 --> 00:41:06,379
and the damage it took
in the strength test.
977
00:41:06,465 --> 00:41:07,922
Those are the reasons
we're letting you go.
978
00:41:08,008 --> 00:41:09,716
- I understand.
Thanks for having me.
979
00:41:09,801 --> 00:41:11,259
- Well, dave, it's clear
980
00:41:11,344 --> 00:41:12,510
you have what it takes
to fight in this forge,
981
00:41:12,596 --> 00:41:14,095
and you're an extremely
talented smith,
982
00:41:14,139 --> 00:41:16,598
but unfortunately, your time
in this competition has ended,
983
00:41:16,683 --> 00:41:18,349
and for that reason,
I'm going to have to ask you
984
00:41:18,435 --> 00:41:20,018
to please step off
the forge floor.
985
00:41:20,103 --> 00:41:22,061
- Good job, man.
986
00:41:22,147 --> 00:41:23,897
I got a ton
out of this experience.
987
00:41:23,982 --> 00:41:25,648
I met some great people.
988
00:41:25,692 --> 00:41:27,150
I got to play
with some techniques
989
00:41:27,194 --> 00:41:29,444
and types of weapons
I would normally not do,
990
00:41:29,529 --> 00:41:33,448
and I had a blast doing it,
so I can't complain at all.
991
00:41:33,533 --> 00:41:35,241
- Well, eric, you know what
that means.
992
00:41:35,327 --> 00:41:37,118
You are the newest
"forged in fire" champion.
993
00:41:37,204 --> 00:41:38,786
You're going to be
walking out of here
994
00:41:38,872 --> 00:41:42,123
with a check for $10,000.
Congratulations.
995
00:41:42,209 --> 00:41:44,000
- I feel awesome
coming out here,
996
00:41:44,044 --> 00:41:47,754
winning the competition,
having my skills validate.
997
00:41:47,839 --> 00:41:49,339
This is a crowning achievement
of mine.
998
00:41:49,424 --> 00:41:52,091
- Well done.
- Thank you.
999
00:41:52,177 --> 00:41:54,219
If somebody wants me
to make a woldo,
1000
00:41:54,304 --> 00:41:55,762
it's going to cost them
10 grand.
1001
00:41:55,847 --> 00:42:02,143
♪ ♪