1 00:00:06,292 --> 00:00:07,625 - Here in The Forge, we've asked smiths 2 00:00:07,708 --> 00:00:09,917 to make Damascus from all kinds of materials. 3 00:00:10,000 --> 00:00:11,083 - [laughs] 4 00:00:11,208 --> 00:00:13,458 - Son of a b****. 5 00:00:13,542 --> 00:00:15,500 - But this time, we're asking them 6 00:00:15,500 --> 00:00:17,417 to use something a little scarier. 7 00:00:17,542 --> 00:00:18,875 - [chuckles] 8 00:00:19,000 --> 00:00:21,083 - How am I gonna make this? Where do I start? 9 00:00:21,083 --> 00:00:22,750 [intense music] 10 00:00:22,833 --> 00:00:25,500 - This is the Frankenstein Damascus challenge. 11 00:00:25,542 --> 00:00:28,083 [high-pitched scream] 12 00:00:29,208 --> 00:00:30,792 [upbeat rock music] 13 00:00:30,875 --> 00:00:32,125 - My name is Stanley Yee. 14 00:00:32,208 --> 00:00:33,833 I'm 46 years old. 15 00:00:33,833 --> 00:00:37,125 I was in the army as a captain for several years. 16 00:00:37,208 --> 00:00:39,000 My time in the military 17 00:00:39,125 --> 00:00:41,500 definitely built up my tolerance for pressure. 18 00:00:41,500 --> 00:00:44,083 From extremely stressful environments 19 00:00:44,208 --> 00:00:47,333 to long, drawn-out processes as well. 20 00:00:47,417 --> 00:00:49,667 ♪ 21 00:00:49,667 --> 00:00:51,208 - My name is Benjamin Bays. 22 00:00:51,292 --> 00:00:54,083 I'm 23 years old, I'm from Downs, Illinois, 23 00:00:54,083 --> 00:00:56,500 and I've been bladesmithing for about six years now. 24 00:00:56,625 --> 00:00:59,292 I first thought when I was in fifth grade, 25 00:00:59,292 --> 00:01:02,250 I could make a sword by melting aluminum cans. 26 00:01:02,375 --> 00:01:04,167 I learned that that doesn't work out very well. 27 00:01:04,292 --> 00:01:06,250 So I would like to say 28 00:01:06,250 --> 00:01:07,667 I've come a long way since then. 29 00:01:07,792 --> 00:01:09,792 [chuckles] 30 00:01:09,792 --> 00:01:10,958 - My name is Erik Greiner. 31 00:01:10,958 --> 00:01:13,667 I'm 36 years old from Lubbock, Texas. 32 00:01:13,667 --> 00:01:15,458 I've been bladesmithing for about eight years. 33 00:01:15,458 --> 00:01:17,708 I was actually born in Namibia, 34 00:01:17,708 --> 00:01:20,500 the country above South Africa on the West Coast. 35 00:01:20,583 --> 00:01:22,667 And when I was one, we moved to the U.S. 36 00:01:22,750 --> 00:01:25,167 I have four little girls. Oldest is 11. 37 00:01:25,250 --> 00:01:27,167 The youngest is 6. 38 00:01:27,167 --> 00:01:29,750 They think making knives is pretty cool. 39 00:01:29,833 --> 00:01:32,292 - My name is Travis Halling. I'm 40 years old. 40 00:01:32,292 --> 00:01:34,917 I've been blacksmithing, bladesmithing, 41 00:01:35,000 --> 00:01:38,000 probably about seven, eight years. 42 00:01:38,083 --> 00:01:39,667 I'm in the Coast Guard full-time. 43 00:01:39,750 --> 00:01:41,208 If I did win, 44 00:01:41,292 --> 00:01:43,042 I really would like to get a press 45 00:01:43,167 --> 00:01:45,917 and save my old dying shoulder. 46 00:01:45,917 --> 00:01:47,375 ♪ 47 00:01:47,375 --> 00:01:49,958 - Bladesmiths, welcome to The Forge. 48 00:01:50,042 --> 00:01:51,708 The four of you are here to compete 49 00:01:51,708 --> 00:01:54,458 in three intense rounds of bladesmithing competition. 50 00:01:54,542 --> 00:01:56,583 Now, after each one of those rounds, I will ask you 51 00:01:56,583 --> 00:01:58,542 to present your work to our panel of expert judges here, 52 00:01:58,625 --> 00:02:00,375 and they are the ones deciding which one of you 53 00:02:00,458 --> 00:02:02,417 is leaving here with the title of "Forged in Fire" champion 54 00:02:02,542 --> 00:02:04,458 and getting a check for $10,000. 55 00:02:04,542 --> 00:02:06,125 ♪ 56 00:02:06,208 --> 00:02:08,000 Now, bladesmiths, you guys are gonna be happy 57 00:02:08,000 --> 00:02:09,583 to hear that today, we want you to make 58 00:02:09,583 --> 00:02:12,417 your signature blade in your signature style. 59 00:02:12,542 --> 00:02:14,208 ♪ 60 00:02:14,292 --> 00:02:17,208 But there is a catch. 61 00:02:17,208 --> 00:02:18,375 Gentlemen, in order to make your blades, 62 00:02:18,500 --> 00:02:20,958 you are going to need this. 63 00:02:21,042 --> 00:02:26,333 ♪ 64 00:02:26,375 --> 00:02:28,875 Bladesmiths, this is a competition we are calling 65 00:02:29,000 --> 00:02:31,417 The Frankenstein Damascus Challenge. 66 00:02:31,542 --> 00:02:34,042 Sitting here in front of me are cutoffs 67 00:02:34,167 --> 00:02:36,458 from competitions over the past few years. 68 00:02:36,542 --> 00:02:39,000 Now, every time a smith has gone to the chop saw, 69 00:02:39,083 --> 00:02:40,750 somebody has been there to pick it up. 70 00:02:40,833 --> 00:02:43,458 Some of this steel was just excess on great billets. 71 00:02:43,542 --> 00:02:46,250 Some of it is riddled with delaminations 72 00:02:46,333 --> 00:02:47,750 or bad forge welds. 73 00:02:47,875 --> 00:02:50,333 Your task today is to select at least three pieces 74 00:02:50,333 --> 00:02:52,875 from this pile here to make your Damascus billets. 75 00:02:52,958 --> 00:02:55,375 - That's just a pile of crappy steel. 76 00:02:55,458 --> 00:02:57,333 [laughs] 77 00:02:57,375 --> 00:02:58,875 That's okay. I can work with that. 78 00:02:58,958 --> 00:03:01,167 ♪ 79 00:03:01,250 --> 00:03:02,583 - And when you turn your blades in, 80 00:03:02,583 --> 00:03:04,667 make sure they fall within these parameters. 81 00:03:04,708 --> 00:03:08,167 Your blade length needs to be between 13 and 15 inches, 82 00:03:08,250 --> 00:03:10,083 and those blades will have to be set up 83 00:03:10,167 --> 00:03:11,583 for a full tang handle construction. 84 00:03:11,708 --> 00:03:13,083 Now, for the three of you joining us 85 00:03:13,167 --> 00:03:14,333 in the second round of this competition, 86 00:03:14,417 --> 00:03:15,292 you will add handles to your blades, 87 00:03:15,625 --> 00:03:17,208 turning them into fully functioning weapons. 88 00:03:17,333 --> 00:03:18,792 We will then check for strength and durability 89 00:03:18,875 --> 00:03:20,583 in an antler chop. 90 00:03:20,583 --> 00:03:24,500 And then for edge retention in a playing card slice. 91 00:03:24,542 --> 00:03:26,333 All right, guys, there are only three hours 92 00:03:26,375 --> 00:03:27,708 on the clock, so good luck. 93 00:03:27,708 --> 00:03:29,125 Your time starts now. 94 00:03:29,208 --> 00:03:31,417 ♪ 95 00:03:31,500 --> 00:03:32,667 Now, these guys have to use 96 00:03:32,667 --> 00:03:34,792 at least three pieces from this pile. 97 00:03:34,875 --> 00:03:37,458 We've got good stuff. We've got really, really bad. 98 00:03:37,458 --> 00:03:40,208 There's one chunk in there that looks like a PayDay bar. 99 00:03:40,208 --> 00:03:43,833 - But they have way more time and way less stress 100 00:03:43,917 --> 00:03:47,333 than the last smith that abandoned this bar, right? 101 00:03:47,458 --> 00:03:49,917 - Big pile of junk steel. 102 00:03:50,000 --> 00:03:53,458 Most of them look like they're about to just blow apart. 103 00:03:53,542 --> 00:03:54,875 It's pretty slim pickings. 104 00:03:54,875 --> 00:03:57,000 - What would be the best and quickest method 105 00:03:57,083 --> 00:03:58,042 for these guys? 106 00:03:58,167 --> 00:03:59,708 - Canister. 107 00:03:59,708 --> 00:04:02,000 Now, these smiths can find the best pieces 108 00:04:02,000 --> 00:04:04,083 that don't have to be that big, 109 00:04:04,083 --> 00:04:06,667 cut them up, clean them up, and drop them in that canister. 110 00:04:06,750 --> 00:04:10,042 And 1095 powder bonds to stuff really nicely. 111 00:04:10,042 --> 00:04:11,375 ♪ 112 00:04:11,458 --> 00:04:13,667 - So I chose canister Damascus. 113 00:04:13,708 --> 00:04:15,667 I'm a little more familiar with it, 114 00:04:15,750 --> 00:04:19,125 and in my experience, I've run into more trouble 115 00:04:19,208 --> 00:04:20,792 forging layered Damascus. 116 00:04:20,875 --> 00:04:22,792 ♪ 117 00:04:22,792 --> 00:04:24,708 - I've made a lot of trash-mascus, 118 00:04:24,708 --> 00:04:27,833 so what I'm gonna try to do is layer it up and pound it out. 119 00:04:27,875 --> 00:04:31,000 - Travis is not setting up to do a canister. 120 00:04:31,042 --> 00:04:33,333 - If you're going to stack and weld, 121 00:04:33,333 --> 00:04:36,458 you have to have that stack cleaned up, 122 00:04:36,458 --> 00:04:38,500 stacked nicely where you don't have a lot of pieces 123 00:04:38,542 --> 00:04:40,000 sticking off in different sizes, 124 00:04:40,000 --> 00:04:41,167 and then weld it up. 125 00:04:41,208 --> 00:04:44,792 ♪ 126 00:04:44,875 --> 00:04:46,583 - It's shocking using discarded steel 127 00:04:46,583 --> 00:04:49,375 because you don't know why it was discarded. 128 00:04:49,458 --> 00:04:51,417 I'm thinking canister on this because I don't 129 00:04:51,500 --> 00:04:54,208 have to rely solely on the Damascus. 130 00:04:54,292 --> 00:04:56,375 I can use the powdered steel. 131 00:04:56,500 --> 00:04:59,667 I know there's some good steel in there somewhere. 132 00:04:59,792 --> 00:05:02,167 Three hours is a crazy time frame. 133 00:05:02,208 --> 00:05:03,250 I don't normally do it this fast, 134 00:05:03,375 --> 00:05:04,667 but I can get it done. 135 00:05:04,792 --> 00:05:07,750 ♪ 136 00:05:07,750 --> 00:05:10,583 - The one and only time I've done canister Damascus, 137 00:05:10,667 --> 00:05:13,042 I used White Out, and the can peeled right off, 138 00:05:13,167 --> 00:05:15,583 and I'm hoping that this time, it's gonna do the same. 139 00:05:15,667 --> 00:05:17,375 - I don't like seeing that White Out. 140 00:05:17,458 --> 00:05:19,375 He's buying himself another 141 00:05:19,458 --> 00:05:21,500 30 minutes of busting that can off 142 00:05:21,542 --> 00:05:23,417 if he doesn't do it right the first time. 143 00:05:23,542 --> 00:05:24,833 - When I'm cleaning the pieces, 144 00:05:24,958 --> 00:05:26,708 there's a few cracks 145 00:05:26,792 --> 00:05:28,292 and cold shuts that stick out to me, 146 00:05:28,375 --> 00:05:30,792 so I just start grinding away on them 147 00:05:30,792 --> 00:05:32,750 and clean it up best as I can to get it ready 148 00:05:32,833 --> 00:05:34,708 to chop up and put in my canister. 149 00:05:34,792 --> 00:05:36,375 - I like that a lot of the bladesmiths 150 00:05:36,375 --> 00:05:38,292 are not just cleaning the steel, 151 00:05:38,375 --> 00:05:40,167 but really examine what you're picking up. 152 00:05:40,250 --> 00:05:45,250 ♪ 153 00:05:45,250 --> 00:05:47,167 - Working with a canister, I need to reach 154 00:05:47,250 --> 00:05:49,125 some good forging temperatures 155 00:05:49,208 --> 00:05:51,000 and making sure the scrap pieces 156 00:05:51,000 --> 00:05:52,625 will forge weld. 157 00:05:52,625 --> 00:05:55,458 If I start too early, it could form cracks. 158 00:05:55,542 --> 00:05:57,125 It could delaminate. 159 00:05:57,208 --> 00:05:58,500 Hot steel! 160 00:05:58,583 --> 00:05:59,667 - Look at that can. 161 00:05:59,750 --> 00:06:01,458 That's the heat you want to see. 162 00:06:01,542 --> 00:06:04,458 - The steel I selected so far is working great. 163 00:06:04,542 --> 00:06:07,250 Nothing disastrous has happened, 164 00:06:07,333 --> 00:06:09,292 so I'm very happy. 165 00:06:09,375 --> 00:06:10,583 - So, guys, right now we've got three smiths 166 00:06:10,667 --> 00:06:12,125 who've committed to a canister 167 00:06:12,208 --> 00:06:14,958 and we've got one who's doing set Damascus pattern. 168 00:06:14,958 --> 00:06:18,333 - After I get my billet to forge welding temperatures, 169 00:06:18,375 --> 00:06:21,750 I choose to set my welds by hand. 170 00:06:21,750 --> 00:06:23,833 I'm very familiar with that. 171 00:06:23,875 --> 00:06:25,958 - Travis is taking a bit of a risk with not having 172 00:06:26,042 --> 00:06:27,958 quite as much steel as the other competitors. 173 00:06:27,958 --> 00:06:29,292 But if he can pull it off, it's bumping him ahead. 174 00:06:29,375 --> 00:06:30,792 - Oh, yeah. 175 00:06:30,792 --> 00:06:32,625 It seems like it's all consolidated. 176 00:06:32,708 --> 00:06:34,917 - You see how he's got that little uneven spot at that tip? 177 00:06:35,000 --> 00:06:36,583 Lose that. 178 00:06:36,583 --> 00:06:39,208 Any problem that develops is gonna start right there. 179 00:06:39,208 --> 00:06:40,500 ♪ 180 00:06:40,542 --> 00:06:42,583 - I'm feeling really good. 181 00:06:42,583 --> 00:06:44,708 All the welds have set, 182 00:06:44,708 --> 00:06:47,667 so now I have to start just drawing this billet out. 183 00:06:47,750 --> 00:06:49,708 - Bladesmiths, one hour has elapsed. 184 00:06:49,708 --> 00:06:51,833 You've got two hours remaining. 185 00:06:51,917 --> 00:06:53,500 ♪ 186 00:06:53,500 --> 00:06:55,500 Erik at the press going for his first weld 187 00:06:55,542 --> 00:06:56,792 on the squaring dies. 188 00:06:56,875 --> 00:06:59,375 - Really nice. He had a good heat. 189 00:06:59,500 --> 00:07:01,542 - Everything's looking solid, 190 00:07:01,625 --> 00:07:03,542 so I start stretching it out. 191 00:07:03,625 --> 00:07:06,458 - Now he's just squishing his can. 192 00:07:06,542 --> 00:07:09,208 - Yeah. - It seems a little aggressive. 193 00:07:09,208 --> 00:07:11,792 - I get done and get to the handle. 194 00:07:11,792 --> 00:07:12,917 [bleep]. 195 00:07:12,917 --> 00:07:14,625 I look at the edges 196 00:07:14,625 --> 00:07:16,208 and they're starting to split open in a couple of spots. 197 00:07:16,208 --> 00:07:18,375 - Uh-oh. 198 00:07:18,375 --> 00:07:20,083 Looks like he's got a bunch of cracking 199 00:07:20,083 --> 00:07:21,292 on the sides of the can. 200 00:07:21,417 --> 00:07:22,708 - Well, he was going aggressive. 201 00:07:22,708 --> 00:07:24,625 - There's the chance that 202 00:07:24,708 --> 00:07:26,625 there is no solid steel in there. 203 00:07:26,708 --> 00:07:29,333 - What may have happened is, when he was 204 00:07:29,333 --> 00:07:31,417 getting really aggressive on the press, 205 00:07:31,500 --> 00:07:33,750 is that he let the heat drain out of that billet. 206 00:07:33,833 --> 00:07:36,292 That's when you're gonna get the metal to actually crack. 207 00:07:36,375 --> 00:07:37,792 - [bleep]. 208 00:07:37,792 --> 00:07:40,000 I keep grinding, I'm not getting any solid steel. 209 00:07:40,083 --> 00:07:41,375 Starting over. 210 00:07:41,375 --> 00:07:42,625 - Uh-oh. 211 00:07:42,625 --> 00:07:45,375 Erik's completely restarting. 212 00:07:45,500 --> 00:07:47,750 - If I kept going with this billet, 213 00:07:47,833 --> 00:07:50,583 I don't think I'd make it to round two. 214 00:07:50,708 --> 00:07:52,083 I'm choosing to stick with canister, 215 00:07:52,208 --> 00:07:55,167 but I'm not gonna go as aggressive on the press, 216 00:07:55,250 --> 00:07:56,958 which is where I screwed up last time. 217 00:07:57,042 --> 00:07:58,958 ♪ 218 00:07:59,042 --> 00:08:00,958 - Ben, back on the press for round number two. 219 00:08:01,042 --> 00:08:03,750 - I see my can folding away from my billet, 220 00:08:03,750 --> 00:08:05,792 so I'm pretty sure that the White Out worked. 221 00:08:05,875 --> 00:08:08,375 - He went to the squaring dies to consolidate it, 222 00:08:08,500 --> 00:08:10,000 but now he's drawing it out on Big Blu. 223 00:08:10,000 --> 00:08:12,000 Is he still gonna be able to get this can off? 224 00:08:12,083 --> 00:08:13,042 - Not as easily. 225 00:08:13,042 --> 00:08:14,875 - [bleep]. 226 00:08:14,875 --> 00:08:17,875 I may have gone a little bit too far on Big Blu. 227 00:08:17,875 --> 00:08:20,583 - Ben is having a hell of a time peeling this can off. 228 00:08:20,708 --> 00:08:23,333 Wonder if he's regretting throwing the White Out in. 229 00:08:23,417 --> 00:08:25,917 ♪ 230 00:08:25,917 --> 00:08:28,792 - I'm too far into this billet to start over, 231 00:08:28,875 --> 00:08:30,333 so I just gotta work with what I got. 232 00:08:30,417 --> 00:08:32,042 ♪ 233 00:08:32,125 --> 00:08:36,625 - Bladesmiths, you have one hour and 30 minutes left. 234 00:08:36,708 --> 00:08:38,375 - So Travis has that little piece 235 00:08:38,375 --> 00:08:39,708 at the end of that billet. 236 00:08:39,833 --> 00:08:42,000 That's just a problem waiting to happen. 237 00:08:42,083 --> 00:08:45,583 - I know that the test is gonna be a chopping test, 238 00:08:45,667 --> 00:08:48,750 so I stick with what I know. 239 00:08:48,833 --> 00:08:52,000 I draw out a Bowie that's gonna have a thicker spine. 240 00:08:52,000 --> 00:08:53,500 ♪ 241 00:08:53,583 --> 00:08:56,417 As I'm making the clip portion of my Bowie knife... 242 00:08:56,417 --> 00:08:57,917 ♪ 243 00:08:57,917 --> 00:08:59,542 [bleep]. 244 00:08:59,542 --> 00:09:02,708 I notice some detrimental delaminations, 245 00:09:02,833 --> 00:09:04,917 and this is not gonna work. 246 00:09:05,000 --> 00:09:06,417 - Oh, no. 247 00:09:06,417 --> 00:09:08,000 We said it was gonna be a problem. 248 00:09:08,083 --> 00:09:11,083 He drew that out without dealing with that, 249 00:09:11,208 --> 00:09:12,250 and now he's dealing with it. 250 00:09:12,250 --> 00:09:13,708 - Oh, he's dealing with it. 251 00:09:13,833 --> 00:09:15,667 - Delaminations on the tip of my knife, 252 00:09:15,708 --> 00:09:18,167 that will be a critical failure. 253 00:09:18,250 --> 00:09:22,833 I don't have enough material to cut that portion off. 254 00:09:22,875 --> 00:09:25,875 I don't know how far those delaminations go. 255 00:09:25,875 --> 00:09:28,000 At this point, this will send me home. 256 00:09:28,083 --> 00:09:30,458 I need to figure this out as soon as possible. 257 00:09:30,542 --> 00:09:31,000 ♪ 258 00:09:35,125 --> 00:09:35,333 Ugh. Okay. 259 00:09:35,792 --> 00:09:37,042 So basically, I figure 260 00:09:37,042 --> 00:09:38,292 if I flip this thing upside down, 261 00:09:38,292 --> 00:09:39,833 I can make a seax. 262 00:09:39,917 --> 00:09:42,000 If it's on the spine, it's not on the cutting edge, 263 00:09:42,042 --> 00:09:44,667 I should not have a catastrophic failure. 264 00:09:44,750 --> 00:09:46,792 - He's working the spine of his blade, 265 00:09:46,792 --> 00:09:48,167 making sure he doesn't have delaminations 266 00:09:48,208 --> 00:09:50,333 running all the way through. 267 00:09:50,333 --> 00:09:53,375 - This is not the original knife I wanted to make. 268 00:09:53,458 --> 00:09:56,667 However, it is what it is at this point. 269 00:09:56,708 --> 00:09:58,250 [rock music] 270 00:09:58,333 --> 00:10:00,417 - Erik restarted his billet. 271 00:10:00,500 --> 00:10:02,083 Instead of just going really aggressive 272 00:10:02,167 --> 00:10:04,875 in one position, he decided to switch 273 00:10:04,875 --> 00:10:06,542 back and forth, even hitting up on the end. 274 00:10:06,667 --> 00:10:08,000 - I'm relieved. 275 00:10:08,042 --> 00:10:10,208 I do not see any of the cracks on the edges 276 00:10:10,292 --> 00:10:11,625 like I did last time. 277 00:10:11,708 --> 00:10:13,167 It's looking good. I'm happy with it. 278 00:10:13,250 --> 00:10:20,333 ♪ 279 00:10:20,417 --> 00:10:22,708 - Finally. - Oh, Ben. 280 00:10:22,792 --> 00:10:24,708 Ben was able to get the rest of that can off his billet, 281 00:10:24,792 --> 00:10:27,167 but he's got a ton of work to do 282 00:10:27,167 --> 00:10:30,458 and far less time than he needs to get it done. 283 00:10:30,542 --> 00:10:32,042 Meanwhile, on the other side of The Forge, 284 00:10:32,042 --> 00:10:34,333 we've got Stanley who's getting very close to a quench. 285 00:10:34,375 --> 00:10:36,042 This is pretty early in the game. 286 00:10:36,125 --> 00:10:38,792 - Profile, not exactly where I want it, 287 00:10:38,875 --> 00:10:40,792 but I need to quench this. 288 00:10:40,875 --> 00:10:43,458 - Stanley has enough time to see, "Oh, no, 289 00:10:43,542 --> 00:10:45,375 "there's mild steel across my edge. 290 00:10:45,500 --> 00:10:46,917 I'll grind that away." 291 00:10:47,000 --> 00:10:50,000 - Not knowing what those scrap pieces of steel are, 292 00:10:50,042 --> 00:10:53,458 quenching could be the source of warping and cracking. 293 00:10:53,542 --> 00:10:54,875 ♪ 294 00:10:54,958 --> 00:10:56,625 - All right, Stanley is in the oil. 295 00:10:56,708 --> 00:10:58,000 30 minutes left on the clock. 296 00:10:58,083 --> 00:11:00,750 - I don't hear any pings or anything. 297 00:11:00,750 --> 00:11:02,875 Now I have to get this mild steel canister off. 298 00:11:03,042 --> 00:11:04,667 - Look at Stanley's blade. 299 00:11:04,708 --> 00:11:06,542 There's a lot of meat right behind that edge 300 00:11:06,542 --> 00:11:08,000 that I'd really like to see him address. 301 00:11:08,042 --> 00:11:10,333 ♪ 302 00:11:10,417 --> 00:11:12,833 - I bet right now, Ben is really wishing he had 303 00:11:12,875 --> 00:11:14,667 that extra 30 minutes that it took him 304 00:11:14,708 --> 00:11:16,333 to put that can together in the first place. 305 00:11:16,333 --> 00:11:18,375 - And that 20 minutes it took to get the can off. 306 00:11:18,458 --> 00:11:20,000 - Yeah. 307 00:11:20,125 --> 00:11:21,458 - [bleep]. 308 00:11:21,542 --> 00:11:23,833 As soon as I set it with my hammer, 309 00:11:23,875 --> 00:11:26,917 I see these cracks forming on one side. 310 00:11:27,042 --> 00:11:30,750 That's the last thing I need on this competition. 311 00:11:30,750 --> 00:11:32,667 It's an issue because I don't want them 312 00:11:32,667 --> 00:11:34,667 to travel all the way through my billet, 313 00:11:34,667 --> 00:11:36,417 and I do not have enough time to start over. 314 00:11:36,500 --> 00:11:38,958 - The fact that it's not breaking into pieces tells me 315 00:11:39,042 --> 00:11:40,958 there's some good welds in there somewhere. 316 00:11:40,958 --> 00:11:43,667 - Just start grinding away on those cracks as best I can 317 00:11:43,750 --> 00:11:46,750 and getting most of them out with my angle grinder. 318 00:11:46,833 --> 00:11:48,917 I have no idea if I'm gonna be able to do this, 319 00:11:49,000 --> 00:11:50,958 but I'm gonna give it a shot. 320 00:11:50,958 --> 00:11:52,792 Clock is ticking and I need to start 321 00:11:52,875 --> 00:11:54,583 getting some progress done. 322 00:11:54,583 --> 00:11:56,125 We're just gonna go for it. 323 00:11:58,958 --> 00:12:01,583 - At this point, I am feeling good. 324 00:12:01,583 --> 00:12:03,875 There's no delaminations anymore. 325 00:12:03,875 --> 00:12:05,542 I'm gonna quench this thing. 326 00:12:05,542 --> 00:12:06,917 ♪ 327 00:12:07,000 --> 00:12:08,333 - Travis has quenched. 328 00:12:08,375 --> 00:12:09,708 ♪ 329 00:12:09,792 --> 00:12:11,667 - Everything seems fairly straight. 330 00:12:11,750 --> 00:12:13,000 Let's get this thing cleaned up. 331 00:12:13,042 --> 00:12:15,000 I'm looking pretty good at this point. 332 00:12:15,083 --> 00:12:17,958 - Gentlemen, you've got 15 minutes remaining. 333 00:12:18,042 --> 00:12:19,208 ♪ 334 00:12:19,333 --> 00:12:20,833 Here we go. 335 00:12:20,917 --> 00:12:22,875 - All right. - All right, Erik in the oil. 336 00:12:22,875 --> 00:12:24,458 Three down, one to go. 337 00:12:24,542 --> 00:12:26,042 - That'll do it. 338 00:12:26,167 --> 00:12:28,250 I've got a hardened blade. It looks straight. 339 00:12:28,375 --> 00:12:30,542 Okay, I have something I can turn in to the judges. 340 00:12:30,542 --> 00:12:32,292 ♪ 341 00:12:32,375 --> 00:12:33,458 - Yeah, buddy. 342 00:12:33,542 --> 00:12:34,833 You did it! 343 00:12:34,875 --> 00:12:36,542 - Yours is looking good. 344 00:12:36,542 --> 00:12:39,000 - What's Stanley working on other than checking out Ben? 345 00:12:39,083 --> 00:12:40,792 - Stanley's working on nothing. 346 00:12:40,792 --> 00:12:43,083 - This is the time to be grinding the shape. 347 00:12:43,167 --> 00:12:44,250 - Whatever it is he needs to do, 348 00:12:44,333 --> 00:12:46,000 he's got a little bit of time to do it. 349 00:12:46,083 --> 00:12:49,625 - I am happy with my blade. I met the parameters. 350 00:12:49,708 --> 00:12:51,500 I feel I've done enough. 351 00:12:51,583 --> 00:12:53,750 - Ben, quench it! [laughs] 352 00:12:53,833 --> 00:12:55,583 - Stanley's rooting him on. - Yeah. 353 00:12:55,667 --> 00:12:57,625 - That'll have to do. 354 00:12:57,708 --> 00:12:59,167 - Ben's giving it everything he's got. 355 00:12:59,250 --> 00:13:01,417 I love seeing it. 356 00:13:01,500 --> 00:13:03,083 There we go. 357 00:13:03,167 --> 00:13:05,625 Ben has a quenched blade, and that thing was hot. 358 00:13:05,708 --> 00:13:07,583 - It's kind of straight. 359 00:13:07,667 --> 00:13:12,208 - Five, four, three, two, one. 360 00:13:12,208 --> 00:13:14,208 Bladesmiths, turn off your machines. 361 00:13:14,292 --> 00:13:16,208 This round is over. 362 00:13:16,292 --> 00:13:17,833 - Whoo! 363 00:13:17,958 --> 00:13:20,208 - I know my blade shape is not pretty, 364 00:13:20,208 --> 00:13:23,667 and I know my finish is far from even close. 365 00:13:23,708 --> 00:13:25,833 I'm just hoping the judges think 366 00:13:25,917 --> 00:13:27,667 that I have something salvageable. 367 00:13:27,667 --> 00:13:29,417 ♪ 368 00:13:29,500 --> 00:13:30,833 - All right, gentlemen, 369 00:13:30,875 --> 00:13:31,917 in the first three hours of this competition, 370 00:13:32,000 --> 00:13:33,875 we gave you a very difficult task 371 00:13:33,958 --> 00:13:35,792 of taking forgotten steel, smashing it together 372 00:13:35,875 --> 00:13:37,333 into your own Frankenstein billets. 373 00:13:37,333 --> 00:13:39,042 The time has come for the judges to take 374 00:13:39,125 --> 00:13:41,167 a closer look at your blades and decide which three of you 375 00:13:41,208 --> 00:13:43,500 are joining us in the second round of this competition. 376 00:13:43,542 --> 00:13:44,500 Stanley, you're up first. 377 00:13:44,583 --> 00:13:45,750 You ready? - Yes. 378 00:13:45,833 --> 00:13:48,042 - Please present your work. 379 00:13:48,042 --> 00:13:50,375 ♪ 380 00:13:50,500 --> 00:13:52,083 - All right, Stanley. 381 00:13:52,083 --> 00:13:54,042 So you did very well with your canister Damascus. 382 00:13:54,167 --> 00:13:55,875 You were way ahead over there. 383 00:13:55,875 --> 00:13:58,000 You drew it out nicely, and then you stopped 384 00:13:58,083 --> 00:14:00,250 with 10 to 15 minutes left to go. 385 00:14:00,250 --> 00:14:02,500 And I say that because, well, 386 00:14:02,583 --> 00:14:04,208 there's so much metal over here, 387 00:14:04,208 --> 00:14:07,125 and there are some delaminations where the can is. 388 00:14:07,208 --> 00:14:08,958 And, you know, using that time that you had, 389 00:14:09,042 --> 00:14:10,417 you could have ground that out. 390 00:14:10,500 --> 00:14:12,833 If you move forward, 391 00:14:12,833 --> 00:14:14,500 you definitely have to refine the handle 392 00:14:14,583 --> 00:14:15,958 and really lighten the blade out 393 00:14:16,042 --> 00:14:18,208 and take out some of these delaminations. 394 00:14:18,292 --> 00:14:19,750 - Thank you. 395 00:14:19,833 --> 00:14:22,542 - All right, Ben, please present your work. 396 00:14:22,625 --> 00:14:24,958 ♪ 397 00:14:25,042 --> 00:14:27,000 - So, Ben, right off, 398 00:14:27,083 --> 00:14:29,625 it's got that great chopper shape to it. 399 00:14:29,625 --> 00:14:32,833 It's got a handle that's scaled properly for my hand, 400 00:14:32,917 --> 00:14:36,167 so your profile's come together very nicely. 401 00:14:36,167 --> 00:14:38,167 You've got a warp in this blade 402 00:14:38,250 --> 00:14:40,417 that's outside of grinder range. 403 00:14:40,500 --> 00:14:42,833 It's something that's gonna have to be fixed with heat. 404 00:14:42,833 --> 00:14:45,917 So if you move forward, a lot of cleanup, 405 00:14:46,042 --> 00:14:48,833 but a really good job of not giving up 406 00:14:48,958 --> 00:14:49,958 and pushing through to the end. 407 00:14:50,042 --> 00:14:51,458 - Thank you. 408 00:14:51,542 --> 00:14:54,583 - Erik, it's your turn. Please present your work. 409 00:14:54,583 --> 00:14:55,875 ♪ 410 00:14:55,875 --> 00:14:57,458 - All right, Erik. 411 00:14:57,458 --> 00:14:59,208 Well, first of all, I got to say nice job 412 00:14:59,208 --> 00:15:00,667 knowing when to start over. 413 00:15:00,708 --> 00:15:01,958 And what you ended up bringing in, 414 00:15:02,042 --> 00:15:03,333 it looks really good. 415 00:15:03,375 --> 00:15:06,250 The welds on the faces look really good. 416 00:15:06,375 --> 00:15:10,208 There's a little bit of can sticking out the side up here, 417 00:15:10,208 --> 00:15:12,250 and some kind of delamination is visible, 418 00:15:12,375 --> 00:15:14,500 but I think the spine just needs some cleanup. 419 00:15:14,583 --> 00:15:18,708 Your handle is about an inch, inch and a half too big. 420 00:15:18,792 --> 00:15:20,833 But I think if you move forward, 421 00:15:20,917 --> 00:15:21,833 you've got a good starting point 422 00:15:21,917 --> 00:15:24,167 to go on from here. 423 00:15:24,250 --> 00:15:25,292 - All right, last up, we got Travis. 424 00:15:25,375 --> 00:15:27,667 Please present your work, sir. 425 00:15:27,708 --> 00:15:28,958 ♪ 426 00:15:28,958 --> 00:15:30,833 - All right, Travis. 427 00:15:30,917 --> 00:15:33,167 So you are the only one who didn't go 428 00:15:33,167 --> 00:15:35,458 with the canister Damascus, but you found good metal 429 00:15:35,542 --> 00:15:37,917 because, I mean, this is solid right here. 430 00:15:37,917 --> 00:15:39,750 Now, you do have some deep hammer marks, 431 00:15:39,750 --> 00:15:41,833 but it's something that you could probably clean up 432 00:15:41,917 --> 00:15:43,333 if you move to the second round. 433 00:15:43,417 --> 00:15:46,667 But overall, good job on being able 434 00:15:46,708 --> 00:15:48,333 to give us a solid piece of steel. 435 00:15:48,417 --> 00:15:50,917 Just a lot of refinement going on to the second round. 436 00:15:52,833 --> 00:15:54,458 - All right, gentlemen, 437 00:15:54,458 --> 00:15:56,167 you guys all have a ton to be proud of, 438 00:15:56,167 --> 00:15:57,792 but as you know, only three of you can join us 439 00:15:57,875 --> 00:15:59,333 in the second round of this competition. 440 00:15:59,417 --> 00:16:01,542 Now, after deliberating and discussing every aspect 441 00:16:01,542 --> 00:16:04,667 of your blades, the judges did make a final decision. 442 00:16:04,750 --> 00:16:06,292 The bladesmith leaving The Forge is... 443 00:16:06,375 --> 00:16:08,708 ♪ 444 00:16:08,792 --> 00:16:10,458 Stanley. 445 00:16:10,458 --> 00:16:12,083 Unfortunately, your blade did not make the cut, 446 00:16:12,167 --> 00:16:13,625 and Ben's gonna tell you why. 447 00:16:13,625 --> 00:16:15,875 - Well, Stanley, you started out this round 448 00:16:15,875 --> 00:16:17,042 really strong, but the blade 449 00:16:17,125 --> 00:16:19,042 that you actually presented to us, 450 00:16:19,042 --> 00:16:20,333 it starts out refined at the tip, 451 00:16:20,458 --> 00:16:22,125 and as you move towards the tang, 452 00:16:22,125 --> 00:16:24,625 it gets less and less refined and bigger and clunkier. 453 00:16:24,625 --> 00:16:26,583 There was some time you had towards the end of the round 454 00:16:26,583 --> 00:16:28,333 where some of that could have been addressed. 455 00:16:28,417 --> 00:16:30,250 Sometimes every minute in this competition 456 00:16:30,333 --> 00:16:32,333 really, really counts, and this is one of those times. 457 00:16:32,417 --> 00:16:33,708 And that's the reason we're letting you go. 458 00:16:33,708 --> 00:16:35,000 - Thank you. 459 00:16:35,042 --> 00:16:36,250 - We want to say thank you for coming out, 460 00:16:36,333 --> 00:16:37,792 fighting so hard in The Forge, 461 00:16:37,875 --> 00:16:39,625 but unfortunately, your time in this competition has ended. 462 00:16:39,708 --> 00:16:41,250 I'm gonna have to ask you to please surrender your work 463 00:16:41,333 --> 00:16:43,667 and step off The Forge floor. 464 00:16:43,750 --> 00:16:46,208 - Looking back, I probably should have spent 465 00:16:46,208 --> 00:16:47,917 just a little more time 466 00:16:47,917 --> 00:16:50,542 just refining it a little more. 467 00:16:50,625 --> 00:16:54,500 I had every intention to just have a great time, 468 00:16:54,583 --> 00:16:57,292 meet some amazing smiths. 469 00:16:57,375 --> 00:17:00,250 But for anyone coming on the competition, 470 00:17:00,333 --> 00:17:02,292 if you've got ten minutes on the clock, 471 00:17:02,292 --> 00:17:04,833 use that ten minutes. 472 00:17:04,917 --> 00:17:09,500 I will make blades until the day I can't make blades. 473 00:17:09,583 --> 00:17:11,667 - All right, gentlemen, congratulations. 474 00:17:11,667 --> 00:17:13,083 The three of you are joining us in the second round 475 00:17:13,083 --> 00:17:14,542 of this competition, where you will fix 476 00:17:14,542 --> 00:17:15,917 any issues that the judges brought up, 477 00:17:15,917 --> 00:17:17,917 refine your blades, and add handles to them, 478 00:17:17,917 --> 00:17:19,750 turning them to fully functioning weapons. 479 00:17:19,833 --> 00:17:21,875 Now, as far as handle materials go, 480 00:17:21,958 --> 00:17:23,500 we are keeping with the Frankenstein theme. 481 00:17:23,583 --> 00:17:26,375 And in order to complete your handles, you'll need this. 482 00:17:26,375 --> 00:17:33,000 ♪ 483 00:17:34,375 --> 00:17:36,208 - What we have here are more discarded pieces 484 00:17:36,208 --> 00:17:37,333 from handle rounds, and you will need to use 485 00:17:37,708 --> 00:17:40,167 at least two of them in the construction of your handles. 486 00:17:40,250 --> 00:17:42,083 - There's not a single piece big enough 487 00:17:42,083 --> 00:17:44,750 to make a whole scale on its own. 488 00:17:44,833 --> 00:17:46,250 This is gonna be frustrating. 489 00:17:46,333 --> 00:17:48,292 - All right, gentlemen, when this round is over, 490 00:17:48,292 --> 00:17:49,750 your blades will go into the hands of our judges 491 00:17:49,833 --> 00:17:51,500 and they will check for strength and durability 492 00:17:51,583 --> 00:17:53,250 in an antler chop. 493 00:17:53,333 --> 00:17:54,500 And then we'll check your edge retention 494 00:17:54,625 --> 00:17:57,167 in a playing card slice. 495 00:17:57,208 --> 00:17:58,542 Gentlemen, you guys have two hours 496 00:17:58,542 --> 00:18:00,667 to complete your blades, and that time starts now. 497 00:18:00,750 --> 00:18:04,208 ♪ 498 00:18:04,208 --> 00:18:06,250 All right, there is a lot of material on that table, 499 00:18:06,333 --> 00:18:09,167 but not a lot of it is really all that useful. 500 00:18:09,250 --> 00:18:11,292 - Whatever you pick up, drop it on the floor. 501 00:18:11,375 --> 00:18:14,250 Because some of these materials were results of materials 502 00:18:14,333 --> 00:18:18,042 breaking open or breaking while they were being used. 503 00:18:18,125 --> 00:18:19,333 - I want to try to use 504 00:18:19,417 --> 00:18:21,750 the simplest material I can find. 505 00:18:21,875 --> 00:18:23,333 I'm looking at cuts. 506 00:18:23,333 --> 00:18:25,042 If there are holes in there, can I fix them? 507 00:18:25,125 --> 00:18:26,833 So I grabbed three pieces of wood. 508 00:18:26,833 --> 00:18:28,625 ♪ 509 00:18:28,625 --> 00:18:31,542 And then I start to refine my blade. 510 00:18:31,625 --> 00:18:33,333 - Travis immediately listening to your critiques 511 00:18:33,375 --> 00:18:34,917 and hogging material out. 512 00:18:35,000 --> 00:18:36,667 - I just keep grinding away, 513 00:18:36,667 --> 00:18:39,167 trying to do the best with what I got at this point. 514 00:18:39,208 --> 00:18:40,833 Come on, baby. 515 00:18:40,917 --> 00:18:42,583 ♪ 516 00:18:42,667 --> 00:18:44,208 - I decided to go with three different pieces 517 00:18:44,292 --> 00:18:46,167 because I could not find two pieces 518 00:18:46,250 --> 00:18:48,792 that were long enough to fit my entire handle. 519 00:18:48,875 --> 00:18:51,417 Ben said I have delamination. 520 00:18:51,500 --> 00:18:53,333 So while my handle material's setting up, 521 00:18:53,375 --> 00:18:55,083 I head to the grinder. 522 00:18:55,083 --> 00:18:57,208 I'm giving myself about 30 minutes 523 00:18:57,292 --> 00:18:59,042 to refine my blade shape. 524 00:18:59,042 --> 00:19:01,167 I'm hoping to start working on the handle 525 00:19:01,167 --> 00:19:03,000 at about an hour and a half left. 526 00:19:03,000 --> 00:19:05,917 ♪ 527 00:19:05,917 --> 00:19:08,667 - Ben's blade, he's got a warp, which he's gonna have to use 528 00:19:08,750 --> 00:19:10,250 some kind of heat to straighten that out. 529 00:19:10,333 --> 00:19:11,625 - He's got a lot of work to do. 530 00:19:11,708 --> 00:19:15,000 - I know I need to fix the warp in my blade. 531 00:19:15,042 --> 00:19:18,250 My goal is to heat my blade's spine up 532 00:19:18,250 --> 00:19:20,208 and keep my edge cool so I don't ruin the temper 533 00:19:20,292 --> 00:19:21,500 of the edge. 534 00:19:21,542 --> 00:19:22,750 ♪ 535 00:19:22,833 --> 00:19:25,833 - And... 536 00:19:25,875 --> 00:19:27,833 - Please be good. 537 00:19:27,917 --> 00:19:30,208 - I'm cranking it just enough 538 00:19:30,292 --> 00:19:32,375 that it doesn't snap the blade in half. 539 00:19:32,375 --> 00:19:35,333 Think that's as good as it's gonna get. 540 00:19:35,333 --> 00:19:39,208 - Bladesmiths, you have one hour and 30 minutes left. 541 00:19:39,208 --> 00:19:42,292 Travis is already working on fitting up his handle. 542 00:19:42,292 --> 00:19:45,833 - At this point, I start popping holes in my tang. 543 00:19:45,833 --> 00:19:48,208 I grab what I think is the right pin stock, 544 00:19:48,208 --> 00:19:50,750 and I just epoxy the bejesus out of it. 545 00:19:50,875 --> 00:19:52,500 I'm having a good time. It is 546 00:19:52,500 --> 00:19:53,708 Any time you're in The Forge, 547 00:19:53,792 --> 00:19:55,500 it's better than a day at work for me. 548 00:19:55,583 --> 00:19:57,625 ♪ 549 00:19:57,708 --> 00:19:59,750 - I want to put a pin through each of these pieces, 550 00:19:59,833 --> 00:20:02,167 make sure I got a strong mechanical connection 551 00:20:02,208 --> 00:20:03,458 so it will be less likely 552 00:20:03,542 --> 00:20:05,500 to break off a piece of material. 553 00:20:05,583 --> 00:20:07,333 I start drilling through the tang 554 00:20:07,375 --> 00:20:09,792 and I'm able to get through it real quick. 555 00:20:09,917 --> 00:20:12,833 Starting to put the handle scales on the handle... 556 00:20:12,917 --> 00:20:14,417 [bleep]. 557 00:20:14,500 --> 00:20:16,167 And one of the pins doesn't fit. 558 00:20:16,250 --> 00:20:18,625 - One of the things Erik has to be careful of is, 559 00:20:18,625 --> 00:20:21,708 his scales are made of three pieces that are glued together. 560 00:20:21,708 --> 00:20:23,750 You start hammering on one section of that, 561 00:20:23,833 --> 00:20:24,958 you could pop that glue. 562 00:20:24,958 --> 00:20:26,417 - Oh, yeah. 563 00:20:26,417 --> 00:20:28,958 - I have epoxy, two pins going through, 564 00:20:29,042 --> 00:20:31,875 and the third one does not go all the way through, 565 00:20:31,875 --> 00:20:35,542 so I stick one pin on either side of the hole 566 00:20:35,625 --> 00:20:37,417 that's not lining up in the hopes that I can 567 00:20:37,417 --> 00:20:39,708 get a little bit of the pin in the hole, 568 00:20:39,708 --> 00:20:42,167 so I can have a bit of a mechanical bond. 569 00:20:42,208 --> 00:20:44,750 It's not ideal, but it's what I've got. 570 00:20:44,833 --> 00:20:47,167 I still need to get an edge on there 571 00:20:47,250 --> 00:20:49,042 and I still need to etch it. 572 00:20:49,042 --> 00:20:53,042 - Bladesmiths, you are down to the final 45 minutes. 573 00:20:53,042 --> 00:20:56,542 - I'm definitely feeling some panic right about now. 574 00:20:56,625 --> 00:20:58,833 I grab two pieces of wood that are long enough 575 00:20:58,917 --> 00:21:00,542 to make two full scales out of, 576 00:21:00,625 --> 00:21:02,708 and I have to get the holes drilled through my tang. 577 00:21:02,833 --> 00:21:05,125 And then I put my handle scale on, and.... 578 00:21:05,208 --> 00:21:07,000 I did not think that through right. 579 00:21:07,083 --> 00:21:09,792 ...run the pins to the wrong side. 580 00:21:09,792 --> 00:21:12,542 So I have to pull them out before the epoxy sets. 581 00:21:12,625 --> 00:21:14,542 - Ben's running into a lot of walls fitting up 582 00:21:14,625 --> 00:21:17,625 his handle scales with the holes in his tang. 583 00:21:17,708 --> 00:21:20,417 - I start running around, and it's about half 584 00:21:20,500 --> 00:21:21,833 trying to get my pin stock through, 585 00:21:21,875 --> 00:21:24,167 and half absolute panic. 586 00:21:24,208 --> 00:21:26,625 - Even if Ben's just got two pins all the way 587 00:21:26,708 --> 00:21:28,792 through both scales and filled the rest with glue, 588 00:21:28,875 --> 00:21:30,542 at least we'd have something to test. 589 00:21:30,542 --> 00:21:32,333 - If I don't get my handle scales on, 590 00:21:32,333 --> 00:21:33,625 I won't have a handle. 591 00:21:33,708 --> 00:21:35,458 Then I'm out of luck. I'm done. 592 00:21:35,542 --> 00:21:39,250 - This looks a lot more like panic to me than intent. 593 00:21:39,375 --> 00:21:41,500 - The clock is ticking and I'm running out of time. 594 00:21:41,542 --> 00:21:41,917 ♪ 595 00:21:46,208 --> 00:21:47,083 - I think Ben is playing, 596 00:21:47,375 --> 00:21:48,917 "get it done, get it done, get it done." 597 00:21:49,000 --> 00:21:51,000 - It might be our most Frankenstein-y blade out there. 598 00:21:51,125 --> 00:21:53,250 - [laughs] - Absolutely. 599 00:21:53,333 --> 00:21:54,917 - Thank God. 600 00:21:55,042 --> 00:21:58,167 I finally get my scales on, but I don't have time to wait 601 00:21:58,167 --> 00:22:01,333 for the epoxy to cure because I have to get my blade sharp, 602 00:22:01,333 --> 00:22:03,958 finish shaping my handle, and get an acid etch. 603 00:22:03,958 --> 00:22:06,542 Not giving up paid off for me last round. 604 00:22:06,625 --> 00:22:09,000 - Bladesmiths, you have 20 minutes remaining 605 00:22:09,042 --> 00:22:11,000 in this round. 606 00:22:11,083 --> 00:22:12,458 - So at this point, I start 607 00:22:12,458 --> 00:22:14,042 removing material on my handle. 608 00:22:14,042 --> 00:22:17,250 One side is super thick, the other one is super thin. 609 00:22:17,375 --> 00:22:19,542 My handle is not exactly where I want it to be, 610 00:22:19,667 --> 00:22:21,375 but I don't want to reshape this handle 611 00:22:21,375 --> 00:22:23,333 because I'll be taking off too much material. 612 00:22:23,417 --> 00:22:26,333 However, I think it'll work for what it is. 613 00:22:26,333 --> 00:22:27,958 Whew. 614 00:22:28,042 --> 00:22:29,333 [rock music] 615 00:22:29,417 --> 00:22:32,042 - I'm looking for a nice round handle 616 00:22:32,167 --> 00:22:33,875 that's not too circular. 617 00:22:33,958 --> 00:22:35,500 I want to make sure it stays in their hand 618 00:22:35,583 --> 00:22:37,167 and doesn't fly off and hit somebody. 619 00:22:37,250 --> 00:22:40,208 - Erik is showing some real efficiency. 620 00:22:40,292 --> 00:22:41,708 - I feel like he's gonna have plenty of time 621 00:22:41,792 --> 00:22:43,500 to get this finished the way he wanted to. 622 00:22:43,542 --> 00:22:44,917 This will be an intentionally finished blade. 623 00:22:44,917 --> 00:22:46,375 - Yup. 624 00:22:46,458 --> 00:22:47,958 - I need to get an edge on this thing, 625 00:22:48,042 --> 00:22:51,333 so I put a nice apple seed grind on there 626 00:22:51,375 --> 00:22:53,833 so this blade can be as sharp as it possibly can. 627 00:22:53,833 --> 00:22:55,208 ♪ 628 00:22:55,208 --> 00:22:59,542 - Five, four, three, two, one. 629 00:22:59,542 --> 00:23:01,000 Bladesmiths, turn off your machines, 630 00:23:01,083 --> 00:23:02,375 put down your tools. 631 00:23:02,375 --> 00:23:03,958 Second round of this competition's over. 632 00:23:04,042 --> 00:23:06,417 [clapping] 633 00:23:06,417 --> 00:23:08,292 - The pins didn't go all the way through. 634 00:23:08,375 --> 00:23:09,917 I did what I could to hopefully get 635 00:23:10,042 --> 00:23:11,417 my handle attached properly, 636 00:23:11,417 --> 00:23:14,000 but I'm not 100% confident in it. 637 00:23:14,042 --> 00:23:17,542 ♪ 638 00:23:17,625 --> 00:23:19,167 - All right, gentlemen, welcome to the strength test, 639 00:23:19,250 --> 00:23:21,417 the antler chop. 640 00:23:21,500 --> 00:23:22,667 Ben, you are up. Are you ready? 641 00:23:22,708 --> 00:23:24,083 - No, but it doesn't matter. 642 00:23:24,167 --> 00:23:25,792 - You're right. It doesn't. 643 00:23:25,875 --> 00:23:28,917 ♪ 644 00:23:29,000 --> 00:23:31,708 - I'm pretty concerned that my knife isn't sharp enough. 645 00:23:31,708 --> 00:23:33,542 The judges get a rusty, 646 00:23:33,625 --> 00:23:35,500 tortured piece of metal to test. 647 00:23:35,542 --> 00:23:37,333 I'm just hoping dumb luck will carry me through 648 00:23:37,375 --> 00:23:38,708 this time again. 649 00:23:38,792 --> 00:23:45,667 ♪ 650 00:23:57,375 --> 00:23:59,500 - So, Ben, right off, the handle's big enough 651 00:23:59,583 --> 00:24:01,708 for my hand, it fits beautifully. 652 00:24:01,708 --> 00:24:04,875 But as you can see, when I was hitting that antler, 653 00:24:04,875 --> 00:24:06,958 each hit looks like it took one chunk out. 654 00:24:07,042 --> 00:24:08,417 I hit it four times. 655 00:24:08,417 --> 00:24:10,333 And you got one, two, three, 656 00:24:10,458 --> 00:24:12,083 and another small divot here--four. 657 00:24:12,083 --> 00:24:14,583 All I can think is that this edge is really brittle. 658 00:24:14,667 --> 00:24:16,125 I have a feeling it's just when you quenched this, 659 00:24:16,208 --> 00:24:17,583 it was really, really hot. 660 00:24:17,708 --> 00:24:19,375 But the feel of it's really fantastic, 661 00:24:19,375 --> 00:24:20,292 so nicely done. 662 00:24:20,375 --> 00:24:21,792 - Thank you. 663 00:24:21,875 --> 00:24:23,333 - All right, Erik, you're up. Are you ready? 664 00:24:23,333 --> 00:24:25,083 - Yes, sir. - Okay, let's do it. 665 00:24:25,083 --> 00:24:28,042 ♪ 666 00:24:28,167 --> 00:24:29,875 - I'm excited to see what my blade does, 667 00:24:30,000 --> 00:24:31,667 but I'm nervous at the same time. 668 00:24:31,792 --> 00:24:34,000 Somebody's beating your knife against an antler. 669 00:24:34,125 --> 00:24:35,375 It's not natural. 670 00:24:35,375 --> 00:24:37,833 I hope it stays together. 671 00:24:37,958 --> 00:24:44,583 ♪ 672 00:24:49,917 --> 00:24:52,083 - All right, Erik. 673 00:24:52,167 --> 00:24:54,542 And this is what happens when you just rely on the glue. 674 00:24:54,667 --> 00:24:56,167 And I can see that you didn't quite get that hole 675 00:24:56,167 --> 00:24:58,750 through there, so you put a pin on either side. 676 00:24:58,833 --> 00:25:00,667 Good cosmetics, but without that pin 677 00:25:00,667 --> 00:25:02,500 stabilizing the handle, 678 00:25:02,500 --> 00:25:05,417 it just blew apart with the force of those blows. 679 00:25:05,500 --> 00:25:07,667 So you're now sort of missing a handle. 680 00:25:07,750 --> 00:25:12,167 ♪ 681 00:25:12,208 --> 00:25:13,417 - All right, Erik. 682 00:25:13,500 --> 00:25:15,500 Because it did break after two strikes, 683 00:25:15,542 --> 00:25:16,708 we consider this a catastrophic failure. 684 00:25:16,792 --> 00:25:18,458 We cannot continue testing. 685 00:25:18,458 --> 00:25:19,917 But you are not out of the fight yet. 686 00:25:20,000 --> 00:25:22,042 In order to continue on, Travis, you're gonna have 687 00:25:22,167 --> 00:25:24,333 to survive two strikes on this same brutal test. 688 00:25:24,375 --> 00:25:25,875 Are you ready? - I think so. 689 00:25:25,875 --> 00:25:28,167 - All right, Dave, take it away. 690 00:25:28,292 --> 00:25:30,500 ♪ 691 00:25:30,625 --> 00:25:32,708 - Can my knife make two strikes? 692 00:25:32,708 --> 00:25:34,917 I'm really not sure. 693 00:25:34,917 --> 00:25:36,667 I start thinking about all the delaminations 694 00:25:36,792 --> 00:25:39,458 in my knife, and hopefully I have 695 00:25:39,542 --> 00:25:46,042 enough material to absorb the shock of this. 696 00:25:46,042 --> 00:25:49,167 ♪ 697 00:25:58,958 --> 00:26:00,375 - All right, Travis, congratulations. 698 00:26:00,375 --> 00:26:02,333 You made it through those two strikes on the antler. 699 00:26:02,417 --> 00:26:04,833 Now, Erik, you fought hard, you gave us a good blade, 700 00:26:04,917 --> 00:26:07,042 but due to the catastrophic failure with your weapon, 701 00:26:07,042 --> 00:26:08,708 at this point in time, we all want to say 702 00:26:08,708 --> 00:26:10,167 thank you for coming out and fighting, 703 00:26:10,208 --> 00:26:11,750 but unfortunately, your time in this competition has ended. 704 00:26:11,750 --> 00:26:12,708 I'm gonna have to ask you to please step off 705 00:26:12,708 --> 00:26:14,167 The Forge floor. 706 00:26:14,208 --> 00:26:15,458 Thank you. - See you, guys. 707 00:26:15,542 --> 00:26:17,917 - Thank you, guys. - Good looking blade. 708 00:26:17,917 --> 00:26:20,042 - Other than the fact that my handle broke 709 00:26:20,125 --> 00:26:22,083 and now it's a baby-sized handle-- 710 00:26:22,208 --> 00:26:24,667 my handle's about the size of my kid's hands-- 711 00:26:24,708 --> 00:26:26,917 it's always good for personal growth 712 00:26:27,042 --> 00:26:29,208 to challenge yourself and do things that are uncomfortable. 713 00:26:29,292 --> 00:26:31,833 I'm happy with what I did and how I did. 714 00:26:31,917 --> 00:26:34,500 I'm grateful I got to be here. 715 00:26:34,542 --> 00:26:36,333 - Ben, Travis, gentlemen, congratulations. 716 00:26:36,375 --> 00:26:37,708 You have now made it into the third 717 00:26:37,833 --> 00:26:39,125 and final round of this competition, 718 00:26:39,208 --> 00:26:40,917 where you're going back to your home forges 719 00:26:40,917 --> 00:26:43,667 for four days to build an iconic weapon from history. 720 00:26:43,750 --> 00:26:45,167 Gentlemen, you're gonna be building this. 721 00:26:45,250 --> 00:26:48,833 ♪ 722 00:26:48,917 --> 00:26:50,708 The Crusaders Bible Falchion. 723 00:26:52,042 --> 00:26:54,042 - [laughs] 724 00:26:54,167 --> 00:26:57,000 - The Crusader Bible Falchion traces its origins back 725 00:26:57,083 --> 00:26:59,708 to the illustrated manuscript called the Crusaders Bible. 726 00:26:59,833 --> 00:27:02,500 It is in these pages that the unique falchion can be seen. 727 00:27:02,625 --> 00:27:04,542 The sword features a spatulated tip 728 00:27:04,667 --> 00:27:06,583 with four points for puncturing armor 729 00:27:06,583 --> 00:27:08,708 and a hook handle to prevent disarming. 730 00:27:08,708 --> 00:27:11,042 This deadly chopping, slashing weapon has been 731 00:27:11,125 --> 00:27:14,167 recreated and redesigned by bladesmiths for centuries. 732 00:27:14,208 --> 00:27:17,042 However, no one knows if it ever existed 733 00:27:17,042 --> 00:27:19,000 before the paintings in the Crusaders Bible. 734 00:27:19,083 --> 00:27:21,167 Today, these iconic illustrations can be seen 735 00:27:21,250 --> 00:27:23,375 in person at the Morgan Library & Museum 736 00:27:23,375 --> 00:27:24,708 in New York City. 737 00:27:24,792 --> 00:27:26,583 - Now, guys, the ones you build 738 00:27:26,667 --> 00:27:28,167 must fall within these parameters. 739 00:27:28,250 --> 00:27:29,833 Your blade length measured from tip 740 00:27:29,917 --> 00:27:31,083 to where the cutting edge ends 741 00:27:31,208 --> 00:27:33,333 needs to be between 21 and 23 inches, 742 00:27:33,500 --> 00:27:35,292 needs to swell to a spatulated tip 743 00:27:35,292 --> 00:27:36,958 and feature four points, 744 00:27:37,042 --> 00:27:38,833 and needs to feature a hooked handle. 745 00:27:38,833 --> 00:27:40,542 - I'm a little bit relieved 746 00:27:40,542 --> 00:27:42,625 that it's not a 5-foot-long sword. 747 00:27:42,708 --> 00:27:46,250 But then I see the weird spatula end of the blade, 748 00:27:46,375 --> 00:27:48,042 and I'm starting to wonder how the hell 749 00:27:48,042 --> 00:27:50,833 I'm gonna shape a billet into that. 750 00:27:50,917 --> 00:27:52,375 - Well, we're excited to see what you bring back, 751 00:27:52,375 --> 00:27:53,542 so good luck. 752 00:27:53,667 --> 00:27:55,042 We will see you both in four days. 753 00:27:55,167 --> 00:27:57,042 - Let's do it. - All right, right on. 754 00:27:58,542 --> 00:28:00,208 [upbeat rock music] 755 00:28:00,292 --> 00:28:02,125 - We're in Kannapolis, North Carolina. 756 00:28:02,208 --> 00:28:03,000 It is day one. 757 00:28:03,083 --> 00:28:04,833 I do get lonely in the shop, 758 00:28:04,875 --> 00:28:07,083 so I had to bring in a couple friends. 759 00:28:07,167 --> 00:28:09,833 My wife makes some amazing artwork. 760 00:28:09,833 --> 00:28:11,875 One of the big reasons why we hit it off, 761 00:28:11,875 --> 00:28:14,750 going to the junkyard and finding metal scrap. 762 00:28:14,875 --> 00:28:17,042 So I have never made anything like this. 763 00:28:17,042 --> 00:28:19,792 This is gonna be my inner core, this 5160. 764 00:28:19,792 --> 00:28:22,167 And then we're gonna do Damascus on the outside. 765 00:28:22,208 --> 00:28:25,417 I'm doing Damascus with a San Mai inner core, 766 00:28:25,417 --> 00:28:29,083 because I think if I keep a 5160 leaf spring steel core, 767 00:28:29,167 --> 00:28:31,167 it will hopefully stand up and be resilient 768 00:28:31,208 --> 00:28:32,792 to the judges' tests. 769 00:28:32,792 --> 00:28:35,667 So in The Forge, they got Big Blu. 770 00:28:35,792 --> 00:28:36,917 I have Little Orange. 771 00:28:36,917 --> 00:28:39,917 It's like taking Big Blu... 772 00:28:40,042 --> 00:28:41,417 actually, it's nothing like taking Big Blu. 773 00:28:41,417 --> 00:28:42,667 It's a little guy. 774 00:28:42,750 --> 00:28:43,792 ♪ 775 00:28:43,792 --> 00:28:45,417 It's five tons, 776 00:28:45,500 --> 00:28:47,708 but it's sure as heck's saving my shoulder and my arm. 777 00:28:47,792 --> 00:28:49,583 At the end of day one, 778 00:28:49,667 --> 00:28:52,417 I have 65 layers of solid steel. 779 00:28:52,500 --> 00:28:54,208 We have way too much material, 780 00:28:54,208 --> 00:28:56,792 but that's really gonna help me refine my shape 781 00:28:56,875 --> 00:28:59,417 into the rough shape that we need by tomorrow. 782 00:28:59,542 --> 00:29:01,583 ♪ 783 00:29:01,667 --> 00:29:03,333 - We're in Downs, Illinois. 784 00:29:03,417 --> 00:29:05,375 I have never made a blade this big before, 785 00:29:05,458 --> 00:29:06,792 so it's gonna be a challenge. 786 00:29:06,792 --> 00:29:10,875 I plan on making San Mai 5160 leaf spring 787 00:29:10,958 --> 00:29:13,292 salvaged from a semi-truck trailer, 788 00:29:13,292 --> 00:29:15,333 and I'll forge that flat and square. 789 00:29:15,417 --> 00:29:18,583 And then my shells are coming from wrought iron wagon wheel. 790 00:29:18,583 --> 00:29:21,375 The wrought iron should have a very pretty wood grain look 791 00:29:21,375 --> 00:29:23,167 by the time I get it ground down and etched. 792 00:29:23,208 --> 00:29:24,708 There we go. 793 00:29:24,708 --> 00:29:26,042 That's good wrought iron temperature. 794 00:29:26,042 --> 00:29:28,208 As I'm forging along.... 795 00:29:28,208 --> 00:29:30,667 Oh, [bleep]. 796 00:29:30,750 --> 00:29:32,667 I'm starting to notice a large crack 797 00:29:32,708 --> 00:29:35,042 forming on one of my pieces of San Mai. 798 00:29:35,042 --> 00:29:36,792 If I'm not able to address this crack, 799 00:29:36,792 --> 00:29:38,167 it's gonna take away 800 00:29:38,250 --> 00:29:39,958 some structural integrity from my blade, 801 00:29:40,042 --> 00:29:42,208 and my blade won't be able to hold up to the testing. 802 00:29:42,208 --> 00:29:43,875 [bleep]. 803 00:29:43,958 --> 00:29:45,500 I don't have time to make a mistake. 804 00:29:45,583 --> 00:29:46,750 ♪ 805 00:29:50,792 --> 00:29:51,833 My plan is to keep flexing it up 806 00:29:51,917 --> 00:29:53,583 and forge weld it down. 807 00:29:53,667 --> 00:29:55,500 It should be welded back together. 808 00:29:55,625 --> 00:29:57,542 Once I put it on the rest of my steel, 809 00:29:57,542 --> 00:29:59,375 it should hold together. 810 00:29:59,458 --> 00:30:01,208 We're about halfway sealed up. 811 00:30:01,292 --> 00:30:04,917 I see that the crack is mostly closed up. 812 00:30:05,000 --> 00:30:07,042 So far, it seems like my billet is 813 00:30:07,042 --> 00:30:08,875 welded tight and everything's holding up. 814 00:30:08,875 --> 00:30:11,083 I just hope my luck carries through. 815 00:30:11,083 --> 00:30:12,500 [upbeat rock music] 816 00:30:12,583 --> 00:30:14,250 - Day number two. 817 00:30:14,250 --> 00:30:16,083 The blade right now is just a hunk of metal. 818 00:30:16,208 --> 00:30:17,875 It is ugly. 819 00:30:17,958 --> 00:30:19,167 Get this thing in the forge 820 00:30:19,250 --> 00:30:21,083 and I'm gonna start drawing this out. 821 00:30:21,167 --> 00:30:22,625 I'm getting to a point where I'm gonna try 822 00:30:22,708 --> 00:30:23,958 to create this handle. 823 00:30:23,958 --> 00:30:26,000 I basically have to make a candy cane 824 00:30:26,083 --> 00:30:28,833 or a horseshoe, start putting a curve in. 825 00:30:28,958 --> 00:30:31,000 I overcompensated and kind of had it come in 826 00:30:31,083 --> 00:30:32,583 a little closer than I thought. 827 00:30:32,583 --> 00:30:34,667 So as I strike here, it's gonna push this around 828 00:30:34,708 --> 00:30:36,500 and flatten it out a little bit. 829 00:30:36,583 --> 00:30:39,500 The curl for the handle, it's not perfect. 830 00:30:39,583 --> 00:30:42,417 I am a little concerned about the ergonomics of this. 831 00:30:42,417 --> 00:30:44,875 The judges do want a handle that fits well 832 00:30:44,875 --> 00:30:46,917 in their hand, but I gotta push through. 833 00:30:46,917 --> 00:30:49,458 I gotta get this blade quenched today. 834 00:30:49,458 --> 00:30:51,500 I want to keep myself on the forward progression 835 00:30:51,542 --> 00:30:52,542 that I'm in right now. 836 00:30:52,625 --> 00:30:55,833 ♪ 837 00:30:55,833 --> 00:30:57,042 I pull it out... 838 00:30:57,125 --> 00:30:58,417 ♪ 839 00:30:58,542 --> 00:30:59,583 Whew! 840 00:30:59,583 --> 00:31:01,292 And we are straight. 841 00:31:01,375 --> 00:31:04,417 That's exactly where I wanted to be at by the end of day two. 842 00:31:04,500 --> 00:31:06,917 - Well, it's day two, and the first thing 843 00:31:06,917 --> 00:31:10,125 I have to do this morning is form that spatulated tip. 844 00:31:10,208 --> 00:31:13,708 I'm using a fullering tool, and I'm hammering my billet. 845 00:31:13,792 --> 00:31:15,500 ♪ 846 00:31:15,583 --> 00:31:18,333 I've got my blade mostly to shape and profile. 847 00:31:18,375 --> 00:31:20,708 It's about time that I start moving on to heat-treat. 848 00:31:20,792 --> 00:31:23,750 ♪ 849 00:31:23,875 --> 00:31:26,500 So then I pull it out to inspect it. 850 00:31:26,583 --> 00:31:28,500 My lines are looking okay. 851 00:31:28,500 --> 00:31:31,542 Just by nature of me flying by the seat of my pants, 852 00:31:31,625 --> 00:31:33,167 I feel like I'm behind schedule, 853 00:31:33,167 --> 00:31:34,958 but I'm hoping I can just pull something out 854 00:31:35,042 --> 00:31:36,333 and make it work. 855 00:31:36,417 --> 00:31:38,292 ♪ 856 00:31:38,292 --> 00:31:39,708 - Day four. 857 00:31:39,792 --> 00:31:41,542 Thing's looking really good. 858 00:31:41,625 --> 00:31:44,000 I'm gonna focus on the handle. 859 00:31:44,083 --> 00:31:46,750 So I got both pieces cut out. My pin's in. 860 00:31:46,833 --> 00:31:48,792 I'm going to start shaping. 861 00:31:48,875 --> 00:31:51,042 I want to make my handle more ergonomic. 862 00:31:51,042 --> 00:31:53,500 It's just not right where I want it at. 863 00:31:53,500 --> 00:31:55,417 I think the only way to really get in here 864 00:31:55,500 --> 00:31:59,833 and do this is with a lot of hand sanding. 865 00:31:59,875 --> 00:32:01,708 I can only do so much with the tools I have 866 00:32:01,792 --> 00:32:04,042 to hit this radius on the inside. 867 00:32:04,125 --> 00:32:05,667 I'm going old school. 868 00:32:05,792 --> 00:32:07,292 I'm going hand sanding on this. 869 00:32:07,292 --> 00:32:09,375 I'm gonna run it through the grids just to get 870 00:32:09,375 --> 00:32:11,208 that groove where it needs to be. 871 00:32:11,208 --> 00:32:14,292 The maple that I have is pretty hard. 872 00:32:14,292 --> 00:32:17,250 I did not know it was gonna be this much of a challenge. 873 00:32:17,250 --> 00:32:19,292 I put a lot of heart and soul into this. 874 00:32:19,375 --> 00:32:21,750 I think I'm good with my blade. 875 00:32:21,833 --> 00:32:25,292 I want to hear Doug say those three little words, 876 00:32:25,375 --> 00:32:27,292 "It will KEAL." 877 00:32:27,375 --> 00:32:29,042 - Day four. 878 00:32:29,167 --> 00:32:32,250 Today, I need to shape my bolster and handle material. 879 00:32:32,375 --> 00:32:35,542 ♪ 880 00:32:35,542 --> 00:32:40,167 Decided to just use a rasp to shape my wood 881 00:32:40,208 --> 00:32:42,167 because it's the only tool that's gonna 882 00:32:42,250 --> 00:32:43,875 fit in there in a timely manner. 883 00:32:43,958 --> 00:32:45,417 I've got my blade finished. 884 00:32:45,417 --> 00:32:47,833 Now it's time to get an edge on this thing. 885 00:32:47,958 --> 00:32:49,833 I still feel that it's 50/50, 886 00:32:49,875 --> 00:32:52,542 but I think I was able to make a pretty blade, 887 00:32:52,625 --> 00:32:55,542 and I'm satisfied with what I got accomplished. 888 00:32:55,625 --> 00:33:00,583 ♪ 889 00:33:00,667 --> 00:33:02,833 - Well, Ben, Travis, gentlemen, welcome back to The Forge. 890 00:33:02,875 --> 00:33:04,333 You guys, it's great to see you. 891 00:33:04,458 --> 00:33:06,500 Now, you just came back from what probably seemed like 892 00:33:06,542 --> 00:33:08,458 four very short days where we asked you 893 00:33:08,458 --> 00:33:10,833 to build the Crusaders Bible Falchion. 894 00:33:10,958 --> 00:33:12,333 Guys, they look beautiful. 895 00:33:12,375 --> 00:33:13,875 They look strong and sharp. 896 00:33:13,875 --> 00:33:15,000 Now, before we get into testing, 897 00:33:15,083 --> 00:33:16,167 we want to hear about these blades. 898 00:33:16,250 --> 00:33:17,792 Ben, how'd it go for you? 899 00:33:17,792 --> 00:33:18,833 - Overall, I think it went all right. 900 00:33:18,917 --> 00:33:20,708 ♪ 901 00:33:20,708 --> 00:33:23,833 I ended up taking some wrought iron wagon tire 902 00:33:23,917 --> 00:33:25,875 and making a San Mai sandwich 903 00:33:25,875 --> 00:33:27,750 with a truck leaf spring in the middle. 904 00:33:27,750 --> 00:33:29,500 - Nice. Now, Travis, how about you? 905 00:33:29,583 --> 00:33:31,375 - Mine went pretty well. Had a couple hiccups. 906 00:33:31,375 --> 00:33:32,833 ♪ 907 00:33:32,875 --> 00:33:35,167 I used 1084 and 15n20. 908 00:33:35,250 --> 00:33:37,208 And I did 32 layers on each side 909 00:33:37,208 --> 00:33:39,458 and put a piece of 5160 in the middle. 910 00:33:39,542 --> 00:33:43,208 The wood is a curly maple that came out of an old dresser. 911 00:33:43,292 --> 00:33:44,750 - Guys, these blades look strong. 912 00:33:44,833 --> 00:33:46,542 They look sharp. They look deadly. 913 00:33:46,542 --> 00:33:48,333 But the best way we know how to find out which one of you 914 00:33:48,333 --> 00:33:49,583 is leaving here today as a champion 915 00:33:49,667 --> 00:33:51,542 is by putting them through a series of tests. 916 00:33:51,625 --> 00:33:53,500 And first off, we've got a KEAL test with Doug. 917 00:33:53,542 --> 00:33:55,542 ♪ 918 00:33:55,625 --> 00:33:59,333 - Bladesmiths, welcome to the KEAL test. 919 00:33:59,375 --> 00:34:01,292 Ben, you're up first. Are you ready for this? 920 00:34:01,375 --> 00:34:02,792 - I'm not, but I hope my blade is. 921 00:34:02,875 --> 00:34:04,500 - All right, let's do it. 922 00:34:04,500 --> 00:34:07,042 - I'm feeling pretty good about my weapon, 923 00:34:07,125 --> 00:34:09,167 but I know my opponent is bringing 924 00:34:09,208 --> 00:34:11,125 a awesome, potent weapon as well, 925 00:34:11,208 --> 00:34:12,875 so I'm not sure what's gonna happen. 926 00:34:12,958 --> 00:34:19,792 ♪ 927 00:34:34,250 --> 00:34:36,417 - All right, Ben, let's talk about your weapon here. 928 00:34:36,500 --> 00:34:38,875 What I like about the handle, it's ovoid enough 929 00:34:38,958 --> 00:34:41,750 to where it fits my hand perfectly. 930 00:34:41,750 --> 00:34:43,458 Your edge is sharp 931 00:34:43,542 --> 00:34:46,833 and it chopped this pig not once, 932 00:34:46,917 --> 00:34:48,292 but twice. 933 00:34:48,375 --> 00:34:51,417 Overall, your weapon, it will KEAL. 934 00:34:51,417 --> 00:34:53,042 ♪ 935 00:34:53,125 --> 00:34:54,417 Travis, your turn, sir. Are you ready? 936 00:34:54,500 --> 00:34:56,083 - Ready as I'm ever gonna be. 937 00:34:56,083 --> 00:34:57,542 - All right, let's do this. 938 00:34:57,625 --> 00:34:58,667 ♪ 939 00:34:58,667 --> 00:34:59,958 - I've hunted some pigs. 940 00:35:00,042 --> 00:35:02,167 They have huge shoulders, big dense bones. 941 00:35:02,250 --> 00:35:04,042 You hit one of those hard bones, 942 00:35:04,125 --> 00:35:05,500 you could pop a weld, 943 00:35:05,583 --> 00:35:07,542 a delamination, you can chip a blade, 944 00:35:07,625 --> 00:35:09,875 but let's see what this thing will do. 945 00:35:09,875 --> 00:35:16,750 ♪ 946 00:35:36,500 --> 00:35:38,208 - All right, Travis, let's talk about your weapon here. 947 00:35:38,333 --> 00:35:40,542 First up, I appreciate 948 00:35:40,625 --> 00:35:43,458 the pattern you have with your Damascus. 949 00:35:43,542 --> 00:35:46,833 Your handle has a cylindrical feel to it. 950 00:35:46,875 --> 00:35:48,417 It's very smooth. 951 00:35:48,417 --> 00:35:51,000 And because it's a forward heavy blade, 952 00:35:51,000 --> 00:35:52,958 it rides back here. 953 00:35:53,042 --> 00:35:56,417 There is nothing for me to be able to get a good retention, 954 00:35:56,500 --> 00:35:59,833 so every strike, I had to adjust a couple of times. 955 00:35:59,958 --> 00:36:02,458 But your edge is sharp. 956 00:36:02,458 --> 00:36:04,000 It chops deep, and as you can see, 957 00:36:04,125 --> 00:36:06,250 it chopped the pig carcass in half. 958 00:36:06,333 --> 00:36:09,833 Overall, your weapon, it will KEAL. 959 00:36:09,875 --> 00:36:11,542 - Thank you, Doug. 960 00:36:11,542 --> 00:36:16,208 ♪ 961 00:36:16,208 --> 00:36:17,833 - Bladesmiths, welcome to the strength test: 962 00:36:17,958 --> 00:36:20,500 the pavilion pole chop. 963 00:36:20,542 --> 00:36:23,167 Not only did we get the crazy shape of your falchions 964 00:36:23,167 --> 00:36:24,500 out of the Crusader Bible, 965 00:36:24,625 --> 00:36:26,542 we also found this test in there. 966 00:36:26,708 --> 00:36:28,708 There's a scene in the Bible where Abraham's forces 967 00:36:28,792 --> 00:36:31,333 are chopping down the tent poles of their enemies. 968 00:36:31,417 --> 00:36:33,375 So we're gonna do the same thing 969 00:36:33,458 --> 00:36:35,542 and see how your Falchions hold up. 970 00:36:35,625 --> 00:36:36,667 Ben, you're up first. You ready? 971 00:36:36,708 --> 00:36:37,750 - As ready as I can be. 972 00:36:37,833 --> 00:36:39,542 - All right. 973 00:36:39,542 --> 00:36:46,417 ♪ 974 00:37:06,208 --> 00:37:08,417 Well, Ben, first off, that's a beautiful piece. 975 00:37:08,500 --> 00:37:10,000 I mean, it really captures the essence 976 00:37:10,083 --> 00:37:11,875 of what's in the Crusader Bible. 977 00:37:11,875 --> 00:37:15,750 The handle is really well-proportioned for my hand. 978 00:37:15,750 --> 00:37:18,167 I'm just touching the hook while I have a comfortable grip 979 00:37:18,208 --> 00:37:20,208 on the rest of the handle, so nice job. 980 00:37:20,208 --> 00:37:22,625 The edge held up great. 981 00:37:22,708 --> 00:37:24,833 All in all, I think it's a spectacular piece. 982 00:37:24,833 --> 00:37:26,667 Nice job. - Thank you. 983 00:37:26,750 --> 00:37:29,375 - All right, Travis. You're up, man. You ready? 984 00:37:29,458 --> 00:37:30,792 - No, but let's do it. 985 00:37:30,792 --> 00:37:32,542 - All right. 986 00:37:32,625 --> 00:37:35,500 - I'm not feeling great, if I'm being honest with you. 987 00:37:35,542 --> 00:37:38,792 Honestly, like, seeing Ben's Falchion perform, 988 00:37:38,875 --> 00:37:41,167 I know I'm behind. 989 00:37:41,167 --> 00:37:42,875 I guess we'll see how it goes. 990 00:37:42,875 --> 00:37:43,333 ♪ 991 00:37:47,375 --> 00:37:49,667 [intense rock music] 992 00:37:49,667 --> 00:37:55,833 ♪ 993 00:38:05,708 --> 00:38:09,167 - All right, Travis, well, your edge held up great. 994 00:38:09,208 --> 00:38:13,500 That being said, the handle, it's really long 995 00:38:13,583 --> 00:38:16,375 and it kind of curves from the beginning. 996 00:38:16,375 --> 00:38:18,167 So as I'm trying to hold up here, you know, 997 00:38:18,208 --> 00:38:20,833 I'm sliding back, and when I close my eyes 998 00:38:20,917 --> 00:38:23,042 and index exactly where I want to be, 999 00:38:23,125 --> 00:38:25,167 it's kicked over by about five degrees. 1000 00:38:25,208 --> 00:38:27,542 So I had to compensate for that. 1001 00:38:27,542 --> 00:38:30,333 That being said, I really think you did a great job 1002 00:38:30,375 --> 00:38:32,750 of capturing the spirit of this particular falchion. 1003 00:38:32,833 --> 00:38:34,875 Nice job. - I appreciate it. Thank you. 1004 00:38:34,875 --> 00:38:36,833 ♪ 1005 00:38:36,917 --> 00:38:38,792 - All right, bladesmiths. 1006 00:38:38,792 --> 00:38:42,167 This is a sharpness test, the zip line sandbag slice. 1007 00:38:42,250 --> 00:38:44,208 ♪ 1008 00:38:44,208 --> 00:38:45,750 Ben, you're up first. You ready for this? 1009 00:38:45,750 --> 00:38:48,750 - Sure. - All right, let's do this. 1010 00:38:48,750 --> 00:38:55,542 ♪ 1011 00:39:10,542 --> 00:39:12,292 - All right, Ben, let's talk about your weapon. 1012 00:39:12,375 --> 00:39:13,917 On the different areas that you have, 1013 00:39:14,042 --> 00:39:17,542 especially on that sweet spot, it cut cleanly on the bag. 1014 00:39:17,708 --> 00:39:20,167 On the lower half over here, metal and resistance, 1015 00:39:20,250 --> 00:39:22,208 but it also cut. 1016 00:39:22,292 --> 00:39:24,750 Overall, your weapon, it will cut. 1017 00:39:24,833 --> 00:39:26,167 - I'll take it. 1018 00:39:26,250 --> 00:39:27,375 - All right, Travis, it's your turn. 1019 00:39:27,458 --> 00:39:28,583 Are you ready? - Oh, I'm ready. 1020 00:39:28,708 --> 00:39:30,333 - All right. Let's do this. 1021 00:39:30,333 --> 00:39:37,417 ♪ 1022 00:39:52,667 --> 00:39:54,750 All right, Travis, once again, cutting with this 1023 00:39:54,750 --> 00:39:58,000 on the sweet spot, it cut cleanly on both bags. 1024 00:39:58,000 --> 00:40:00,250 Go a bit lower on this section right here, 1025 00:40:00,333 --> 00:40:02,250 it cuts, but not all the way through. 1026 00:40:02,333 --> 00:40:05,042 Overall, your weapon, sir, it will cut. 1027 00:40:05,125 --> 00:40:06,833 - Thank you. 1028 00:40:06,917 --> 00:40:09,250 - Well, well, well. 1029 00:40:09,333 --> 00:40:10,625 All right, gentlemen, I gotta say 1030 00:40:10,708 --> 00:40:12,333 that this is the kind of competition we love 1031 00:40:12,417 --> 00:40:13,875 to see here in "Forged in Fire". 1032 00:40:13,958 --> 00:40:15,708 But at the end of the day, only one of you guys 1033 00:40:15,708 --> 00:40:17,292 can leave here with the title of "Forged in Fire" champion 1034 00:40:17,292 --> 00:40:19,667 and get that check for $10,000. 1035 00:40:19,750 --> 00:40:21,292 Today's "Forged in Fire" champion is... 1036 00:40:21,375 --> 00:40:24,458 ♪ 1037 00:40:24,458 --> 00:40:26,833 Ben. Congratulations. 1038 00:40:26,917 --> 00:40:28,625 Travis, you were beat out by just this much, 1039 00:40:28,708 --> 00:40:30,500 and Ben's gonna tell you why. 1040 00:40:30,583 --> 00:40:32,375 - Well, Travis, you brought us a Damascus 1041 00:40:32,375 --> 00:40:34,500 San Mai blade that was both beautiful and sharp. 1042 00:40:34,500 --> 00:40:35,917 But at the end of the day, this came down 1043 00:40:35,917 --> 00:40:36,875 to your handle design. 1044 00:40:36,875 --> 00:40:38,708 It was harder for us to control, 1045 00:40:38,708 --> 00:40:40,500 and that affected its performance in the tests. 1046 00:40:40,625 --> 00:40:41,542 And that's why we're letting you go. 1047 00:40:41,667 --> 00:40:43,500 - I completely agree. 1048 00:40:43,500 --> 00:40:45,333 - Well, Travis, I hope you had as much fun 1049 00:40:45,417 --> 00:40:47,375 as we had watching you in the first two rounds. 1050 00:40:47,500 --> 00:40:49,083 We want to say thank you for coming out, 1051 00:40:49,167 --> 00:40:50,750 but unfortunately, your time in this competition has ended. 1052 00:40:50,750 --> 00:40:52,000 I'm gonna have to ask you to please 1053 00:40:52,042 --> 00:40:53,042 step off The Forge floor. 1054 00:40:53,125 --> 00:40:55,000 Thank you. 1055 00:40:55,000 --> 00:40:56,833 - Awesome. 1056 00:40:56,875 --> 00:40:58,917 - It was an amazing experience, 1057 00:40:59,000 --> 00:41:02,167 but my handle just was not where it needed to be. 1058 00:41:02,292 --> 00:41:04,792 And Ben knocked it out of the park. 1059 00:41:04,792 --> 00:41:07,375 I'm going home, give my wife a hug and kiss 1060 00:41:07,500 --> 00:41:09,417 and tell my boys, Daddy didn't win, 1061 00:41:09,500 --> 00:41:10,833 but that's all right, you know? 1062 00:41:11,000 --> 00:41:12,000 He made it here. 1063 00:41:12,042 --> 00:41:13,333 That's a prize in itself. 1064 00:41:13,375 --> 00:41:15,500 ♪ 1065 00:41:15,500 --> 00:41:16,833 - Well, Ben, congratulations. 1066 00:41:16,917 --> 00:41:18,542 That makes you a "Forged in Fire" champion. 1067 00:41:18,542 --> 00:41:19,917 You'll be receiving a check for $10,000. 1068 00:41:20,042 --> 00:41:21,167 Congratulations. 1069 00:41:21,208 --> 00:41:22,750 [clapping] - Thank you. All right. 1070 00:41:22,750 --> 00:41:24,583 I did not at all expect that I would 1071 00:41:24,667 --> 00:41:26,958 make it to the end, but here we are. 1072 00:41:27,042 --> 00:41:29,500 Every step of the way of this process, 1073 00:41:29,583 --> 00:41:31,833 there's been some sort of challenge or hiccup 1074 00:41:31,833 --> 00:41:34,792 that I've had to deal with, but I'm just so grateful 1075 00:41:34,792 --> 00:41:37,333 I got the opportunity and I won, 1076 00:41:37,417 --> 00:41:38,958 so I'm happier than I could ever be. 1077 00:41:39,042 --> 00:41:44,125 ♪