1 00:00:01,740 --> 00:00:04,613 [fire crackling] 2 00:00:06,397 --> 00:00:08,008 [rock music] 3 00:00:08,138 --> 00:00:10,271 - Tonight on a special edition of "Forged in Fire"... 4 00:00:10,401 --> 00:00:11,707 [sirens wail] 5 00:00:11,837 --> 00:00:13,883 Today we are honoring first responders, 6 00:00:14,014 --> 00:00:17,191 those who run toward danger when others are running away. 7 00:00:17,321 --> 00:00:19,802 Four first responders are called into The Forge 8 00:00:19,932 --> 00:00:21,586 to compete in a series of challenges 9 00:00:21,717 --> 00:00:23,197 where every second counts. 10 00:00:23,327 --> 00:00:24,981 - Your glove's on fire, dude. 11 00:00:26,548 --> 00:00:28,680 - Who will be left standing when the smoke clears, 12 00:00:28,811 --> 00:00:31,074 earning the "Forged in Fire" title and 10 grand? 13 00:00:31,205 --> 00:00:32,162 [loud metallic clank] 14 00:00:32,293 --> 00:00:35,165 [rock music] 15 00:00:35,296 --> 00:00:41,954 ♪ 16 00:00:42,085 --> 00:00:44,783 - My name is Britt Barnes. I'm from Newport, Tennessee. 17 00:00:44,914 --> 00:00:47,047 I'm currently a full-time bladesmith. 18 00:00:47,177 --> 00:00:49,310 I spent 20 years with the Border Patrol. 19 00:00:49,440 --> 00:00:51,921 A lot of times, you're miles from any help, 20 00:00:52,052 --> 00:00:56,273 and so carrying knives was just kind of part of the job. 21 00:00:56,404 --> 00:00:58,232 I think if you can get through the Border Patrol Academy, 22 00:00:58,362 --> 00:00:59,842 you can get through just about anything. 23 00:00:59,972 --> 00:01:01,365 It's probably one of the toughest academies 24 00:01:01,496 --> 00:01:02,453 on the planet. 25 00:01:02,584 --> 00:01:03,846 ♪ 26 00:01:03,976 --> 00:01:05,282 - My name is Mark Casina 27 00:01:05,413 --> 00:01:07,023 and I live in Fort Campbell, Kentucky. 28 00:01:07,154 --> 00:01:09,547 And I've been bladesmithing for seven years. 29 00:01:09,678 --> 00:01:11,462 I'm in the Army. 30 00:01:11,593 --> 00:01:14,378 I work alongside the first responders for Fort Campbell. 31 00:01:14,509 --> 00:01:16,119 ♪ 32 00:01:16,250 --> 00:01:18,121 It's very satisfying working with the military police 33 00:01:18,252 --> 00:01:20,341 because when they respond to an emergency 34 00:01:20,471 --> 00:01:22,473 and help someone, you're a part of a team. 35 00:01:22,604 --> 00:01:24,171 ♪ 36 00:01:24,301 --> 00:01:26,173 - My name is Chris Campbell. I'm from South Florida. 37 00:01:26,303 --> 00:01:28,436 I've been blacksmithing for two years. 38 00:01:28,566 --> 00:01:32,092 And I'm EMS Chief for the fire rescue department in my area. 39 00:01:32,222 --> 00:01:33,919 My job is the greatest job on the planet. 40 00:01:34,050 --> 00:01:36,574 You get to have a profound effect on people's lives. 41 00:01:36,705 --> 00:01:38,576 You have to be absolutely focused 42 00:01:38,707 --> 00:01:40,100 and get through whatever is thrown your way. 43 00:01:40,230 --> 00:01:41,231 It changes every shift. 44 00:01:41,362 --> 00:01:42,102 You never know what's gonna happen. 45 00:01:42,232 --> 00:01:43,973 ♪ 46 00:01:44,104 --> 00:01:45,975 - My name's Forest Hansen. I'm from Hemet, California. 47 00:01:46,106 --> 00:01:47,368 I'm a retired fire captain, 48 00:01:47,498 --> 00:01:50,284 and I've been bladesmithing about six years. 49 00:01:50,414 --> 00:01:52,460 It's extremely important for a firefighter to have 50 00:01:52,590 --> 00:01:54,201 at least one good pocket knife, 51 00:01:54,331 --> 00:01:56,072 or maybe even a rescue knife 52 00:01:56,203 --> 00:01:57,813 for, like, cutting a seat belt. 53 00:01:57,943 --> 00:02:00,381 So it's very important to have a good blade. 54 00:02:00,511 --> 00:02:03,166 - First responders, welcome to The Forge. 55 00:02:03,297 --> 00:02:05,342 You're here to engage in three timed rounds 56 00:02:05,473 --> 00:02:07,170 of edged weapon making competition 57 00:02:07,301 --> 00:02:09,433 specifically designed to push the boundaries 58 00:02:09,564 --> 00:02:11,522 of what is possible in bladesmithing, 59 00:02:11,653 --> 00:02:13,611 all in front of a panel of expert judges. 60 00:02:13,742 --> 00:02:15,004 Let's meet them now. 61 00:02:15,135 --> 00:02:16,701 Up first, two-time "Forged in Fire" champion, 62 00:02:16,832 --> 00:02:18,181 Ben Abbott. 63 00:02:18,312 --> 00:02:20,488 Next, historic weapons re-creation specialist, 64 00:02:20,618 --> 00:02:22,142 David Baker. 65 00:02:22,272 --> 00:02:24,753 And last, Kali martial artist, Doug Marcaida. 66 00:02:24,883 --> 00:02:26,798 ♪ 67 00:02:26,929 --> 00:02:29,061 Today, we are honoring first responders, 68 00:02:29,192 --> 00:02:32,064 those who run toward danger when others are running away. 69 00:02:32,195 --> 00:02:34,632 Your first task is to work together 70 00:02:34,763 --> 00:02:36,852 to reveal your first round challenge. 71 00:02:36,982 --> 00:02:38,941 So let's go ahead and step forward. 72 00:02:39,071 --> 00:02:42,466 On the count of three. One, two three. 73 00:02:42,597 --> 00:02:46,949 ♪ 74 00:02:47,079 --> 00:02:48,951 [laughter] 75 00:02:49,081 --> 00:02:52,259 What you see here is an old-timey fire rescue cart. 76 00:02:52,389 --> 00:02:53,782 - Our eyes are going all over it. 77 00:02:53,912 --> 00:02:56,350 Can we use the bell? Can we use the axes? 78 00:02:56,480 --> 00:02:58,003 What's this challenge gonna be? 79 00:02:58,134 --> 00:03:00,136 - Your job is to harvest the high carbon steel 80 00:03:00,267 --> 00:03:02,138 from the rescue tools on this cart 81 00:03:02,269 --> 00:03:04,358 and combine them with the mild steel 82 00:03:04,488 --> 00:03:05,707 from the ladder on this cart 83 00:03:05,837 --> 00:03:07,491 to make a San Mai billet, 84 00:03:07,622 --> 00:03:09,667 from which you will forge a tactical blade 85 00:03:09,798 --> 00:03:12,496 that is between 12 and 14 inches in length. 86 00:03:12,627 --> 00:03:15,325 And it should have a through-tang design. 87 00:03:15,456 --> 00:03:17,458 - A tactical blade is basically any blade design 88 00:03:17,588 --> 00:03:20,200 that can be used in a tactical situation, 89 00:03:20,330 --> 00:03:23,464 whether that's an arrest or recovering narcotics. 90 00:03:23,594 --> 00:03:25,205 - If you make it to the second round, 91 00:03:25,335 --> 00:03:26,641 you'll attach handles to those blades, 92 00:03:26,771 --> 00:03:28,425 and we'll test them for strength and durability 93 00:03:28,556 --> 00:03:29,948 in a burning log chop, 94 00:03:30,079 --> 00:03:32,821 and for edge retention in a rope slice. 95 00:03:32,951 --> 00:03:34,518 Gentlemen, you have just three hours 96 00:03:34,649 --> 00:03:35,867 in this first round of competition 97 00:03:35,998 --> 00:03:38,000 in which to complete all of your work. 98 00:03:38,130 --> 00:03:41,395 Good luck, bladesmiths. Your three hours starts now. 99 00:03:41,525 --> 00:03:42,570 [sirens wail] 100 00:03:42,700 --> 00:03:45,268 [ambient music] 101 00:03:45,399 --> 00:03:47,009 - You wanna get that side? I'll get this side. 102 00:03:47,139 --> 00:03:48,358 - The first thing these guys gotta do 103 00:03:48,489 --> 00:03:50,142 is harvest that steel. 104 00:03:50,273 --> 00:03:51,883 - And bring it down. - Ooh, heavy. 105 00:03:52,014 --> 00:03:54,146 - There's plenty of mild steel on that ladder. 106 00:03:54,277 --> 00:03:56,105 What do you grab? The rungs or the sides? 107 00:03:56,236 --> 00:03:58,238 - I would grab the sides 'cause they're already set up as flat. 108 00:03:58,368 --> 00:03:59,543 ♪ 109 00:03:59,674 --> 00:04:01,937 - Work together. - Yup, get a grinder. 110 00:04:02,067 --> 00:04:04,069 - Working together is something that's gonna be instinctive 111 00:04:04,200 --> 00:04:05,027 for first responders. 112 00:04:05,157 --> 00:04:06,333 It just happens. 113 00:04:06,463 --> 00:04:07,725 We automatically get in that groove, 114 00:04:07,856 --> 00:04:09,074 and we're gonna go to it. 115 00:04:09,205 --> 00:04:11,773 - All these guys working together to chop down 116 00:04:11,903 --> 00:04:13,644 the mild steel on this ladder. 117 00:04:13,775 --> 00:04:14,776 ♪ 118 00:04:14,906 --> 00:04:15,994 - We're communicating. 119 00:04:16,125 --> 00:04:17,213 "Hey, you do this. You do this." 120 00:04:17,344 --> 00:04:19,171 ♪ 121 00:04:19,302 --> 00:04:21,304 - When we work together and we destroy those things quickly, 122 00:04:21,435 --> 00:04:22,523 and everybody has steel in no time. 123 00:04:22,653 --> 00:04:24,220 ♪ 124 00:04:24,351 --> 00:04:26,440 - As soon as I heard the parameters of the challenge, 125 00:04:26,570 --> 00:04:28,964 I know that I'm gonna make a tactical chopper. 126 00:04:29,094 --> 00:04:31,096 - So we're asking these guys to make a tactical knife. 127 00:04:31,227 --> 00:04:33,751 We're not telling them what it is that makes a blade tactical. 128 00:04:33,882 --> 00:04:36,058 It's gonna be their interpretation of the word. 129 00:04:36,188 --> 00:04:38,626 I mean, it can be as literal as saying 130 00:04:38,756 --> 00:04:40,192 it has to do with military tactics. 131 00:04:40,323 --> 00:04:42,369 Or it could be a tactical deployment 132 00:04:42,499 --> 00:04:44,501 of a flat smasher or whatever. 133 00:04:44,632 --> 00:04:46,851 - So the first thing I do is I grab two crowbars. 134 00:04:46,982 --> 00:04:49,463 I know that if I cut these reasonably equal in half, 135 00:04:49,593 --> 00:04:51,073 that everybody's gonna have plenty of metal 136 00:04:51,203 --> 00:04:52,727 to make what they need to make. 137 00:04:52,857 --> 00:04:56,644 - It's almost like these guys chose the crowbars together 138 00:04:56,774 --> 00:04:58,298 as a group. 139 00:04:58,428 --> 00:05:00,561 Like, "This is the steel that we're gonna work with." 140 00:05:00,691 --> 00:05:03,346 - He's got about two feet of crowbar there he's drawing out. 141 00:05:03,477 --> 00:05:05,087 - It's a taco San Mai. 142 00:05:05,217 --> 00:05:07,350 We've got our hardenable steel for the inside, 143 00:05:07,481 --> 00:05:09,091 mild steel on the outside. 144 00:05:09,221 --> 00:05:12,790 ♪ 145 00:05:12,921 --> 00:05:15,227 - My game plan for this knife is to make a Ka-Bar 146 00:05:15,358 --> 00:05:17,317 because it's the essence of tactical. 147 00:05:17,447 --> 00:05:19,667 Marines use them, and that's tactical enough for me. 148 00:05:19,797 --> 00:05:22,800 The plan is, split this mild steel ladder in half, 149 00:05:22,931 --> 00:05:24,759 get it nice and clean. 150 00:05:24,889 --> 00:05:26,282 Two on the outside, two on the outside, 151 00:05:26,413 --> 00:05:27,849 high carbon in the middle. 152 00:05:27,979 --> 00:05:29,938 I know I need to get these forge welds tight. 153 00:05:30,068 --> 00:05:32,636 And without clean steel touching clean steel, 154 00:05:32,767 --> 00:05:35,247 I know I'm gonna have cold shuts. 155 00:05:35,378 --> 00:05:36,466 - What I like about what Chris did is 156 00:05:36,597 --> 00:05:39,295 he cut things into rectangular pieces, 157 00:05:39,426 --> 00:05:41,341 cleaned them all very well with a grinder, 158 00:05:41,471 --> 00:05:43,038 and then stacking them all up. 159 00:05:43,168 --> 00:05:45,475 - That would be, in my opinion, the best way to go. 160 00:05:45,606 --> 00:05:46,650 - Yeah. 161 00:05:46,781 --> 00:05:48,522 ♪ 162 00:05:48,652 --> 00:05:51,133 - I think the best option for me would be 163 00:05:51,263 --> 00:05:52,700 using the taco method 164 00:05:52,830 --> 00:05:55,920 to cut away a letter "C" with my mild steel. 165 00:05:56,051 --> 00:05:58,358 And then stick the high carbon in it, and then press it down. 166 00:05:58,488 --> 00:05:59,663 ♪ 167 00:05:59,794 --> 00:06:01,099 Ah, [bleep]. 168 00:06:01,230 --> 00:06:03,537 I did not tack-weld it together. 169 00:06:03,667 --> 00:06:05,582 And I think "That's okay. I've cleaned it. 170 00:06:05,713 --> 00:06:08,890 "I can heat both pieces to almost a white color, 171 00:06:09,020 --> 00:06:10,848 "and then I can use the press just enough 172 00:06:10,979 --> 00:06:13,721 "to get that shape around the high carbon steel, 173 00:06:13,851 --> 00:06:16,376 just to make sure that that weld actually holds." 174 00:06:16,506 --> 00:06:19,117 - He put that folded over staple of steel, 175 00:06:19,248 --> 00:06:21,032 no MIG welding to hold it still. 176 00:06:21,163 --> 00:06:23,383 It's a really, really difficult way to make that stick. 177 00:06:23,513 --> 00:06:25,297 - I don't know Ben Abbott ever did this twice. 178 00:06:25,428 --> 00:06:26,821 [laughter] 179 00:06:26,951 --> 00:06:29,171 [sirens wail] 180 00:06:29,301 --> 00:06:31,303 - I'd have thought what I'm going to do is 181 00:06:31,434 --> 00:06:33,262 a version of a drop point hunter. 182 00:06:33,393 --> 00:06:35,699 I've done a few San Mais. I haven't done a lot of them. 183 00:06:35,830 --> 00:06:37,745 With a little luck, I'll get it done. 184 00:06:37,875 --> 00:06:40,356 My plan is, is to get my mild kind of flattened out. 185 00:06:40,487 --> 00:06:41,879 And then, I'm gonna wrap it around the outside 186 00:06:42,010 --> 00:06:43,228 of the hardenable steel. 187 00:06:43,359 --> 00:06:44,491 And then, I'm gonna weld it. 188 00:06:44,621 --> 00:06:46,580 So I've got my taco started, 189 00:06:46,710 --> 00:06:48,277 and I've got my hardenable steel flattened out. 190 00:06:48,408 --> 00:06:49,539 I go to try to insert it. 191 00:06:49,670 --> 00:06:50,975 ♪ 192 00:06:51,106 --> 00:06:52,455 Come on, man. 193 00:06:52,586 --> 00:06:54,283 The proper technical term for what I have 194 00:06:54,414 --> 00:06:56,241 is my taco is cattywampus. 195 00:06:56,372 --> 00:06:57,721 - Aw, dang it. Come on. 196 00:06:57,852 --> 00:06:59,331 - There's gonna be a lot of forge scale 197 00:06:59,462 --> 00:07:00,768 on that taco that he built up. 198 00:07:00,898 --> 00:07:02,465 He did no cleaning. 199 00:07:02,596 --> 00:07:05,860 So the question is, is whether that's gonna weld up or not. 200 00:07:05,990 --> 00:07:07,252 - That'll do. 201 00:07:07,383 --> 00:07:09,167 Let's get up to welding temp. Come on. 202 00:07:09,298 --> 00:07:11,561 - Bladesmiths, one hour has elapsed. 203 00:07:11,692 --> 00:07:12,867 You have two hours left. 204 00:07:12,997 --> 00:07:14,608 ♪ 205 00:07:14,738 --> 00:07:16,827 - I'm going to bring everything up to welding temp 206 00:07:16,958 --> 00:07:19,177 and go over to the press, and just squeeze it together. 207 00:07:19,308 --> 00:07:20,265 ♪ 208 00:07:20,396 --> 00:07:22,093 As we know with tacos, 209 00:07:22,224 --> 00:07:24,748 sometimes if you handle them wrong, you lose your filling. 210 00:07:24,879 --> 00:07:26,228 And I'm losing my filling. 211 00:07:26,358 --> 00:07:27,577 - Forest didn't clean his steels 212 00:07:27,708 --> 00:07:29,144 before he started to weld this San Mai, 213 00:07:29,274 --> 00:07:30,928 and so, in my experience, 214 00:07:31,059 --> 00:07:33,888 that just doesn't allow the weld to take very well. 215 00:07:34,018 --> 00:07:36,412 - Reflux it, and I go over to Big Blu. 216 00:07:36,543 --> 00:07:38,893 I'm able to tap that in just nice. 217 00:07:39,023 --> 00:07:41,025 Now I'm in much better shape. 218 00:07:41,156 --> 00:07:43,854 Can we do something easy? - [laughs] 219 00:07:43,985 --> 00:07:46,466 - Yeah, please? Like, like save a life. 220 00:07:46,596 --> 00:07:47,989 ♪ 221 00:07:48,119 --> 00:07:51,819 - Looking at the blade, and my heart sinks. 222 00:07:51,949 --> 00:07:56,084 The welds didn't seem to take, so I tried to take a chisel 223 00:07:56,214 --> 00:07:59,087 and a hammer to see how much of it isn't welded. 224 00:07:59,217 --> 00:08:00,784 ♪ 225 00:08:00,915 --> 00:08:02,220 That's bad. [laughs] 226 00:08:02,351 --> 00:08:04,135 - Mark just chiseled opened his blade. 227 00:08:04,266 --> 00:08:06,529 I mean, that mild steel did not forge-weld at all. 228 00:08:06,660 --> 00:08:08,618 - I only have two layers. 229 00:08:08,749 --> 00:08:10,402 And if I don't make the three layers, 230 00:08:10,533 --> 00:08:12,317 the judges are gonna send me home. 231 00:08:12,448 --> 00:08:14,668 So I take a small piece of mild steel, 232 00:08:14,798 --> 00:08:16,931 and I put it near the back of the blade. 233 00:08:17,061 --> 00:08:19,324 So I would almost have, just a San Mai 234 00:08:19,455 --> 00:08:20,804 by the base of the blade. 235 00:08:20,935 --> 00:08:22,850 - What he's doing right now is a bad idea 236 00:08:22,980 --> 00:08:25,505 because no matter how he forge-welds that together, 237 00:08:25,635 --> 00:08:28,333 he's not gonna get the surfaces of those materials 238 00:08:28,464 --> 00:08:30,684 to even up in a welded fashion. 239 00:08:30,814 --> 00:08:33,817 His glove's on fire as well. Your glove's on fire, dude. 240 00:08:33,948 --> 00:08:34,949 ♪ 241 00:08:35,079 --> 00:08:35,993 - Yeah, buddy. 242 00:08:36,124 --> 00:08:38,474 [laughter] 243 00:08:38,605 --> 00:08:40,258 ♪ 244 00:08:40,389 --> 00:08:41,608 - Every weld seems like it's set. 245 00:08:41,738 --> 00:08:43,261 ♪ 246 00:08:43,392 --> 00:08:45,786 I'm gonna go to Big Blu, stretch it out a little bit. 247 00:08:45,916 --> 00:08:47,265 Give me some length, but not too much 248 00:08:47,396 --> 00:08:48,876 because it's already pretty thin. 249 00:08:49,006 --> 00:08:52,053 - It's disappointing how long and narrow Chris' knife is. 250 00:08:52,183 --> 00:08:54,272 I would love to see more mass on it, to be honest with you. 251 00:08:54,403 --> 00:08:56,100 - The plan was not to be narrow. 252 00:08:56,231 --> 00:08:57,972 I wanted it to be a much bigger blade, 253 00:08:58,102 --> 00:08:59,669 and I just gotta run with it. 254 00:08:59,800 --> 00:09:03,020 So my focus is going to be to keep the spine wide, 255 00:09:03,151 --> 00:09:05,806 and make a sharp blade that's still gonna be strong. 256 00:09:05,936 --> 00:09:07,285 - We're used to doing the impossible 257 00:09:07,416 --> 00:09:08,678 with little or nothing, right? 258 00:09:08,809 --> 00:09:10,201 - Lives is different than steel, though. 259 00:09:10,332 --> 00:09:11,376 I'm okay with lives. 260 00:09:11,507 --> 00:09:13,335 ♪ 261 00:09:13,465 --> 00:09:16,033 - I go over to the press and I start pressing the mild steel. 262 00:09:16,164 --> 00:09:19,036 And I realize that it has shifted. 263 00:09:19,167 --> 00:09:21,473 - That internal steel should be welded. 264 00:09:21,604 --> 00:09:23,519 - You gotta weld for daddy. 265 00:09:23,650 --> 00:09:25,390 If you've got a gap, there is a possibility 266 00:09:25,521 --> 00:09:26,914 you can get a cold shut in there. 267 00:09:27,044 --> 00:09:28,959 As long as my sides are good and welded, I'm okay. 268 00:09:29,090 --> 00:09:31,396 I can always grind off the top. 269 00:09:31,527 --> 00:09:33,050 - Britt's really going after that blade 270 00:09:33,181 --> 00:09:34,225 with that angle grinder. 271 00:09:34,356 --> 00:09:35,357 ♪ 272 00:09:35,487 --> 00:09:37,228 60 minutes, bladesmiths. 273 00:09:37,359 --> 00:09:38,403 ♪ 274 00:09:38,534 --> 00:09:40,275 - As I'm shaping the blade up, 275 00:09:40,405 --> 00:09:43,670 I notice the inside of the taco has not welded up. 276 00:09:43,800 --> 00:09:46,411 - Well, look at that delam he's got at the front of that blade. 277 00:09:46,542 --> 00:09:47,848 It's huge. 278 00:09:47,978 --> 00:09:50,198 - If I don't get the weld along the spine right, 279 00:09:50,328 --> 00:09:52,374 it's gonna, it'll just blow apart. 280 00:09:52,504 --> 00:09:54,811 Not too many chances for a U-turn now. 281 00:09:54,942 --> 00:09:57,335 I'm gonna have to make this work. 282 00:09:57,466 --> 00:09:59,294 I just wanna make sure it's welded up good and tight, 283 00:09:59,424 --> 00:10:01,035 so I take her over to Big Blu. 284 00:10:01,165 --> 00:10:03,864 Give a little love. It's looking pretty darn good. 285 00:10:03,994 --> 00:10:06,780 It's actually looking a little better than I thought. 286 00:10:06,910 --> 00:10:09,783 ♪ 287 00:10:09,913 --> 00:10:12,046 - I'm working my tip into the edge of the blade 288 00:10:12,176 --> 00:10:14,135 and starting to profile out the shape. 289 00:10:14,265 --> 00:10:15,658 Damn it. 290 00:10:15,789 --> 00:10:17,268 I'm looking at my steel. I measure it out. 291 00:10:17,399 --> 00:10:19,357 I don't have nearly enough steel to make my tang. 292 00:10:19,488 --> 00:10:21,185 It's not gonna work. It's too small. 293 00:10:21,316 --> 00:10:22,796 - There's just not enough steel there. 294 00:10:22,926 --> 00:10:25,102 - Chris doesn't know where to attack this thing. 295 00:10:25,233 --> 00:10:26,887 He doesn't know what he wants to do. 296 00:10:27,017 --> 00:10:28,410 - I'm in trouble. 297 00:10:28,540 --> 00:10:29,846 I need to make sure I'm within parameters, 298 00:10:29,977 --> 00:10:30,934 or I'm gonna go home. 299 00:10:31,065 --> 00:10:35,330 ♪ 300 00:10:35,460 --> 00:10:37,767 - I need extra length. I got enough of the blade. 301 00:10:37,898 --> 00:10:40,509 Pull out some mild steel and weld on a tang. 302 00:10:40,640 --> 00:10:41,945 ♪ 303 00:10:42,076 --> 00:10:43,991 I like the idea of using a mild steel tang. 304 00:10:44,121 --> 00:10:47,168 It's not gonna cause any vibration issues to the blade 305 00:10:47,298 --> 00:10:48,822 because it's not super hard. 306 00:10:48,952 --> 00:10:51,128 - Putting a lot of heat and a lot of focus in that tang 307 00:10:51,259 --> 00:10:52,956 to ricasso junction. 308 00:10:53,087 --> 00:10:55,829 Do you suspect that this is a weak spot for him? 309 00:10:55,959 --> 00:10:57,918 - As it currently stands, it is certainly a big weak spot. 310 00:10:58,048 --> 00:11:00,311 - I'm just hoping the handle doesn't fly apart. 311 00:11:00,442 --> 00:11:01,661 It's not horrible. 312 00:11:01,791 --> 00:11:03,358 - Back in the ball game. 313 00:11:03,488 --> 00:11:04,881 It looks like it welded, 314 00:11:05,012 --> 00:11:07,144 so I'm thinking I'm gonna be okay. 315 00:11:07,275 --> 00:11:10,495 So now I'm trying to shape the knife and profile it. 316 00:11:10,626 --> 00:11:13,368 My plan is to do a tactical fighter knife. 317 00:11:13,498 --> 00:11:15,109 So I'm looking at the tang, 318 00:11:15,239 --> 00:11:17,720 and I'm a little worried that it's gonna be too thin. 319 00:11:17,851 --> 00:11:20,027 I want to keep it kind of wide. 320 00:11:20,157 --> 00:11:23,683 Otherwise, it might crack when the judges test the blade. 321 00:11:23,813 --> 00:11:26,163 - It seems like a setup that's more complementary 322 00:11:26,294 --> 00:11:30,254 to a full tang blade than an actual through-tang. 323 00:11:30,385 --> 00:11:31,429 - I think that'll work. 324 00:11:31,560 --> 00:11:32,953 ♪ 325 00:11:33,083 --> 00:11:34,650 - I think I've got a pretty good weld. 326 00:11:34,781 --> 00:11:37,218 So now I'm gonna work on the profile of the blade. 327 00:11:37,348 --> 00:11:38,393 ♪ 328 00:11:38,523 --> 00:11:39,873 For a drop point hunter, 329 00:11:40,003 --> 00:11:42,658 the design of that particular blade shape, 330 00:11:42,789 --> 00:11:45,182 it supports the cutting edge really well for toughness, 331 00:11:45,313 --> 00:11:47,489 and it supports the point really well for stabbing. 332 00:11:47,619 --> 00:11:49,926 It's basically a good all-around shape 333 00:11:50,057 --> 00:11:51,885 for a little bit of everything. 334 00:11:52,015 --> 00:11:53,713 Finally gotta grind a little more, 335 00:11:53,843 --> 00:11:55,584 and then get it heat-treated. 336 00:11:55,715 --> 00:11:58,065 ♪ 337 00:11:58,195 --> 00:11:59,893 - Mark just quenched over here. 338 00:12:00,023 --> 00:12:01,111 - When I pull this blade out, 339 00:12:01,242 --> 00:12:02,504 it started to bend a little bit, 340 00:12:02,634 --> 00:12:03,679 so I don't waste any time. 341 00:12:03,810 --> 00:12:06,638 I go straight over to the vise. [grunts] 342 00:12:06,769 --> 00:12:09,293 I look down the blade, and it's pretty straight. 343 00:12:09,424 --> 00:12:10,904 ♪ 344 00:12:11,034 --> 00:12:12,340 I'll take it. 345 00:12:12,470 --> 00:12:13,645 ♪ 346 00:12:13,776 --> 00:12:14,995 - Now it's time for heat-treat. 347 00:12:15,125 --> 00:12:17,301 My biggest concern right now is that I've got 348 00:12:17,432 --> 00:12:20,391 differential metals that aren't welded perfectly. 349 00:12:20,522 --> 00:12:23,307 And they're gonna expand and contract at different rates. 350 00:12:23,438 --> 00:12:24,874 And I'm nervous because 351 00:12:25,005 --> 00:12:26,833 I really have no idea what's gonna happen. 352 00:12:26,963 --> 00:12:29,139 ♪ 353 00:12:29,270 --> 00:12:30,706 Good. 354 00:12:30,837 --> 00:12:32,229 Everything's looking pretty damn good. 355 00:12:32,360 --> 00:12:34,318 I am relieved beyond measure at the moment. 356 00:12:34,449 --> 00:12:35,667 ♪ 357 00:12:35,798 --> 00:12:37,408 - Chris over here heating up his oil, 358 00:12:37,539 --> 00:12:39,236 getting ready for the quench. 359 00:12:39,367 --> 00:12:42,152 - I got a blade that's ground, my bevels are in. 360 00:12:42,283 --> 00:12:43,763 I fixed a bunch of different things. 361 00:12:43,893 --> 00:12:44,807 It's time to go to heat treat. 362 00:12:44,938 --> 00:12:47,462 ♪ 363 00:12:49,159 --> 00:12:52,162 Oh, yeah. Rock on. 364 00:12:52,293 --> 00:12:54,077 I check it with a file. It skates. 365 00:12:54,208 --> 00:12:55,513 ♪ 366 00:12:55,644 --> 00:12:57,428 - Is Chris putting in serrations on his blade? 367 00:12:57,559 --> 00:12:58,908 - I think so. 368 00:12:59,039 --> 00:13:01,128 - I'm putting saw teeth in on the spine 369 00:13:01,258 --> 00:13:02,433 to make it look more tactical 370 00:13:02,564 --> 00:13:04,218 and look a little more militaristic. 371 00:13:04,348 --> 00:13:05,219 - Pretty cool. 372 00:13:05,349 --> 00:13:06,611 ♪ 373 00:13:06,742 --> 00:13:08,309 - Ten minutes! 374 00:13:08,439 --> 00:13:10,746 - As I'm normalizing, I'm noticing that every time 375 00:13:10,877 --> 00:13:13,227 I pull out, the blade is curving to one side. 376 00:13:13,357 --> 00:13:15,185 - You could see that warp just developing-- 377 00:13:15,316 --> 00:13:17,622 - Oh, wow. - As the steel cools down. 378 00:13:17,753 --> 00:13:19,624 - This is not gonna be good. 379 00:13:19,755 --> 00:13:22,497 I'm gonna have a massive warp on this thing when I quench it. 380 00:13:22,627 --> 00:13:25,369 All the grinding on the planet isn't gonna fix this [bleep]. 381 00:13:25,500 --> 00:13:27,197 I'm thinking the best thing I can do 382 00:13:27,328 --> 00:13:30,592 is get it a little bit hotter on the non-warp side, 383 00:13:30,722 --> 00:13:33,247 so it'll pull a little harder to that side. 384 00:13:33,377 --> 00:13:35,423 ♪ 385 00:13:35,553 --> 00:13:37,991 I pull my blade out. It's got a kink to the left. 386 00:13:38,121 --> 00:13:39,209 [bleep]. Dang it. 387 00:13:39,340 --> 00:13:41,385 - I think it's warped like a ski. 388 00:13:41,516 --> 00:13:43,648 - So the only thing I can think of is to stick the knife back 389 00:13:43,779 --> 00:13:45,737 in the forge, edge up, 390 00:13:45,868 --> 00:13:49,393 and just get my edge at quench temp. 391 00:13:49,524 --> 00:13:51,352 I pull that thing out, and the warp is there, 392 00:13:51,482 --> 00:13:53,049 but it's not nearly as bad. 393 00:13:53,180 --> 00:13:54,355 So I run over to the post vise. 394 00:13:54,485 --> 00:13:55,443 [grunts] 395 00:13:55,573 --> 00:13:57,010 ♪ 396 00:13:57,140 --> 00:13:58,011 Hell, yeah. That'll work. 397 00:13:58,141 --> 00:13:59,055 That'll work. That'll work. 398 00:13:59,186 --> 00:14:00,535 Sure enough, it's pretty straight. 399 00:14:00,665 --> 00:14:05,801 I can live with it. - Five, four, three, two, one. 400 00:14:05,932 --> 00:14:07,803 Bladesmiths, shut down your machines, drop your tools. 401 00:14:07,934 --> 00:14:11,328 This first round of competition is over. 402 00:14:11,459 --> 00:14:13,809 - I'd rather be in a gun fight than go through that again. 403 00:14:13,940 --> 00:14:15,245 That was tough. 404 00:14:15,376 --> 00:14:17,160 I made a knife in three hours. 405 00:14:17,291 --> 00:14:19,162 Not a great knife, but it's a decent knife. 406 00:14:19,293 --> 00:14:21,599 ♪ 407 00:14:21,730 --> 00:14:22,905 - All right, bladesmiths. 408 00:14:23,036 --> 00:14:24,472 In this first round of competition, 409 00:14:24,602 --> 00:14:27,736 you were asked to produce San Mai tactical blades 410 00:14:27,867 --> 00:14:30,173 between 12 and 14 inches in length 411 00:14:30,304 --> 00:14:31,653 with through-tang setups. 412 00:14:31,783 --> 00:14:34,047 Now it's time for the judges to take a closer look. 413 00:14:34,177 --> 00:14:35,309 Forest, you're up first. 414 00:14:35,439 --> 00:14:37,006 Please present your blade to the judges. 415 00:14:37,137 --> 00:14:38,660 ♪ 416 00:14:38,790 --> 00:14:40,531 - Well, Forest, I really like what I see here. 417 00:14:40,662 --> 00:14:43,491 There's a nice amount of height, there's a fair weight. 418 00:14:43,621 --> 00:14:45,841 But there's a couple of delaminations down here 419 00:14:45,972 --> 00:14:47,495 near the ricasso. 420 00:14:47,625 --> 00:14:49,714 There's also the fact that all the way down the spine, 421 00:14:49,845 --> 00:14:51,586 it never welded in the center. 422 00:14:51,716 --> 00:14:54,241 This isn't in a place that, in my mind, causes me any worry 423 00:14:54,371 --> 00:14:55,895 from a structural standpoint. 424 00:14:56,025 --> 00:14:57,505 All in all, I think you did a good job. 425 00:14:57,635 --> 00:14:59,333 - Thank you. - You're up, Chris. 426 00:14:59,463 --> 00:15:01,248 Please present your blade to the judges. 427 00:15:01,378 --> 00:15:02,945 ♪ 428 00:15:03,076 --> 00:15:04,077 - Well, Chris, I liked your setup 429 00:15:04,207 --> 00:15:05,992 with the stack and the weld. 430 00:15:06,122 --> 00:15:08,690 You know, it's a good way to get a San Mai. 431 00:15:08,820 --> 00:15:10,866 I just wish those pieces were a little bit wider 432 00:15:10,997 --> 00:15:12,215 when you started out. 433 00:15:12,346 --> 00:15:13,303 It would've been nice to see 434 00:15:13,434 --> 00:15:14,826 a little bit more height than this. 435 00:15:14,957 --> 00:15:17,090 - I can see here where you welded that mild steel rod 436 00:15:17,220 --> 00:15:18,743 to your existing tang. 437 00:15:18,874 --> 00:15:21,355 And there's an incomplete portion of the weld right here. 438 00:15:21,485 --> 00:15:22,791 And this is a pretty critical area 439 00:15:22,922 --> 00:15:24,053 for the strength of your blade, 440 00:15:24,184 --> 00:15:25,750 so if you were to move forward from here, 441 00:15:25,881 --> 00:15:27,970 I would make it as strong as it could be. 442 00:15:28,101 --> 00:15:30,190 - Yes, sir. - Mark, you're up. 443 00:15:30,320 --> 00:15:31,626 Please present your blade to the judges. 444 00:15:31,756 --> 00:15:33,671 ♪ 445 00:15:33,802 --> 00:15:36,022 - Mark, right off, I do like this profile. 446 00:15:36,152 --> 00:15:38,720 Unfortunately, we saw you struggle with that San Mai, 447 00:15:38,850 --> 00:15:41,375 and at one point, you lost the entire side. 448 00:15:41,505 --> 00:15:42,724 - Yes, sir. 449 00:15:42,854 --> 00:15:44,682 - And went back and put in a section. 450 00:15:44,813 --> 00:15:48,077 But that sectional San Mai kind of causes its own problems. 451 00:15:48,208 --> 00:15:50,166 Right here, the hardenable steel in the center 452 00:15:50,297 --> 00:15:52,473 has been pushed down so thin, 453 00:15:52,603 --> 00:15:55,911 that this right here is the thinnest portion of your blade, 454 00:15:56,042 --> 00:15:58,958 which is gonna take a lot of the brunt of any chopping. 455 00:15:59,088 --> 00:16:00,568 - Also, the tang setup 456 00:16:00,698 --> 00:16:02,570 feels like it's a full tang right now. 457 00:16:02,700 --> 00:16:04,050 We'd like to see some shoulders on that 458 00:16:04,180 --> 00:16:06,400 so we could make it a true through-tang. 459 00:16:06,530 --> 00:16:08,228 - Thank you. - Britt, you're up. 460 00:16:08,358 --> 00:16:10,186 Please present your blade to the judges. 461 00:16:10,317 --> 00:16:11,709 ♪ 462 00:16:11,840 --> 00:16:13,450 - Okay, Britt, looking at your edge here, 463 00:16:13,581 --> 00:16:15,365 it wobbles right here toward the end. 464 00:16:15,496 --> 00:16:16,932 Also, you have some delaminations here 465 00:16:17,063 --> 00:16:18,455 that are coming out. 466 00:16:18,586 --> 00:16:19,935 Dealing with this, 467 00:16:20,066 --> 00:16:21,328 just be careful not to take any more out. 468 00:16:21,458 --> 00:16:22,807 It's a very light blade as it is, 469 00:16:22,938 --> 00:16:25,158 and you need that, have to be able to slash with it. 470 00:16:25,288 --> 00:16:27,769 But I do like the design and your setup for a through-tang. 471 00:16:27,899 --> 00:16:29,336 Thank you. - Yes, sir. 472 00:16:29,466 --> 00:16:31,207 ♪ 473 00:16:31,338 --> 00:16:33,601 - Bladesmiths, the judges' deliberation is complete. 474 00:16:33,731 --> 00:16:35,603 The bladesmith leaving The Forge is... 475 00:16:35,733 --> 00:16:38,171 ♪ 476 00:16:38,301 --> 00:16:40,738 Mark, your blade didn't make the cut. 477 00:16:40,869 --> 00:16:43,263 - Mark, I really applaud all that work you put in 478 00:16:43,393 --> 00:16:45,961 to try to fix that major delamination you had. 479 00:16:46,092 --> 00:16:48,311 But your fix didn't really stick well, 480 00:16:48,442 --> 00:16:51,184 and your blade, of all four blades, has 481 00:16:51,314 --> 00:16:54,230 the least mild steel traveling the length of the blade. 482 00:16:54,361 --> 00:16:55,927 That and the fact that 483 00:16:56,058 --> 00:16:58,234 it's not truly set up as a through-tang at this point. 484 00:16:58,365 --> 00:17:00,062 It needs the most refinement out of all of our blades, 485 00:17:00,193 --> 00:17:01,716 and that's why we're letting you go. 486 00:17:01,846 --> 00:17:03,022 - I understand. 487 00:17:03,152 --> 00:17:04,719 - Mark, please surrender your blade. 488 00:17:04,849 --> 00:17:06,547 ♪ 489 00:17:06,677 --> 00:17:10,029 - I respect their decisions. I think they're correct. 490 00:17:10,159 --> 00:17:13,641 It wasn't enough mild steel to be an actual San Mai. 491 00:17:13,771 --> 00:17:15,730 I came here to prove that I can do this 492 00:17:15,860 --> 00:17:18,167 and I can make a really good knife. 493 00:17:18,298 --> 00:17:20,517 And yes, I believe that I accomplished that. 494 00:17:20,648 --> 00:17:22,389 I'm not going home the winner today, 495 00:17:22,519 --> 00:17:23,433 but I gave it my all. 496 00:17:23,564 --> 00:17:26,306 ♪ 497 00:17:26,436 --> 00:17:27,872 - Congratulations, bladesmiths. 498 00:17:28,003 --> 00:17:30,136 You've made it into the second round of this competition. 499 00:17:30,266 --> 00:17:31,876 And now that those blades have been tempered, 500 00:17:32,007 --> 00:17:34,270 it's time to make them fully functional tactical knives. 501 00:17:34,401 --> 00:17:36,794 You must have a stacked handle construction 502 00:17:36,925 --> 00:17:40,233 using only the rescue equipment found over here in our pantry. 503 00:17:40,363 --> 00:17:43,845 That's the boots, helmets, jackets, and fire hoses 504 00:17:43,975 --> 00:17:46,674 to finish your handles' overall construction. 505 00:17:46,804 --> 00:17:48,154 - I'm familiar with all that material. 506 00:17:48,284 --> 00:17:50,678 I'm in the fire department for 27 years, 507 00:17:50,808 --> 00:17:52,462 so I know it's good, strong material 508 00:17:52,593 --> 00:17:54,464 and it's gonna hold up to anything. 509 00:17:54,595 --> 00:17:56,075 - You have just two hours in this round 510 00:17:56,205 --> 00:17:57,685 to accomplish that task. 511 00:17:57,815 --> 00:18:00,383 Upon completion of this second round's construction, 512 00:18:00,514 --> 00:18:02,603 your blades will be tested for strength and durability 513 00:18:02,733 --> 00:18:04,126 in a fire log chop, 514 00:18:04,257 --> 00:18:07,347 and for edge retention in a rope slice. 515 00:18:07,477 --> 00:18:08,913 After your blades have been tested, 516 00:18:09,044 --> 00:18:11,220 one of you will have to surrender your tactical knife 517 00:18:11,351 --> 00:18:12,743 and leave The Forge. 518 00:18:12,874 --> 00:18:14,441 Good luck, bladesmiths. Your two hours starts now. 519 00:18:14,571 --> 00:18:17,139 ♪ 520 00:18:17,270 --> 00:18:19,446 All right, so these guys have two hours 521 00:18:19,576 --> 00:18:21,839 to complete these stacked handles 522 00:18:21,970 --> 00:18:24,494 using this rescue material over here. 523 00:18:24,625 --> 00:18:26,061 - Give me a hand, would you? - Yeah. 524 00:18:26,192 --> 00:18:28,107 - I think this is great that Britt and Forest 525 00:18:28,237 --> 00:18:30,065 are over here helping each other out. 526 00:18:30,196 --> 00:18:31,806 - It's looking like Chris has got 527 00:18:31,936 --> 00:18:34,374 a few more things to address than we do on our blades, 528 00:18:34,504 --> 00:18:36,506 so we're gonna go ahead and cut up the material 529 00:18:36,637 --> 00:18:38,117 off the fire hose for all of us. 530 00:18:38,247 --> 00:18:39,335 We've got five more to go. 531 00:18:39,466 --> 00:18:40,858 - Forest does the math 532 00:18:40,989 --> 00:18:43,600 and says we need eight slices per smith. 533 00:18:43,731 --> 00:18:46,037 - I'm thinking that much times three. 534 00:18:46,168 --> 00:18:47,909 Worst case, you got plenty. Got it? 535 00:18:48,039 --> 00:18:48,910 - Fantastic. Thanks, buddy. 536 00:18:49,040 --> 00:18:50,825 - You got it. 537 00:18:50,955 --> 00:18:53,044 - The way the materials were provided by my friends here, 538 00:18:53,175 --> 00:18:54,524 we're all watching each other's back. 539 00:18:54,655 --> 00:18:55,569 And it's really nice to see that. 540 00:18:55,699 --> 00:18:57,136 ♪ 541 00:18:57,266 --> 00:18:58,746 I started with the weld because the judges said, 542 00:18:58,876 --> 00:19:00,269 "Watch that weld." 543 00:19:00,400 --> 00:19:01,966 And I'm gonna listen to what the judges tell me 544 00:19:02,097 --> 00:19:03,838 and try to address the issues that they had. 545 00:19:03,968 --> 00:19:05,231 - What is the worry here? 546 00:19:05,361 --> 00:19:07,102 - Where the weld touched the high carbon steel, 547 00:19:07,233 --> 00:19:09,235 it could've cooled rapidly enough to harden it. 548 00:19:09,365 --> 00:19:11,106 And it might snap at that junction. 549 00:19:11,237 --> 00:19:13,064 [sirens wail] 550 00:19:13,195 --> 00:19:14,544 - Forest is coming away from the pantry 551 00:19:14,675 --> 00:19:15,719 with a little bit of mild steel 552 00:19:15,850 --> 00:19:18,157 to use as either a guard or a butt cap. 553 00:19:18,287 --> 00:19:21,943 That's allowable, as long as he uses only this equipment 554 00:19:22,073 --> 00:19:23,945 in the body of the handle. 555 00:19:24,075 --> 00:19:26,861 - I'm gonna make my guard first and get that fitted. 556 00:19:26,991 --> 00:19:28,515 This'll be my front guard. 557 00:19:28,645 --> 00:19:31,213 Might have to modify the blade a little bit to fit, 558 00:19:31,344 --> 00:19:33,128 but that's, that's an important spot. 559 00:19:33,259 --> 00:19:34,651 ♪ 560 00:19:34,782 --> 00:19:37,437 Then I'm gonna punch holes in my handle material. 561 00:19:37,567 --> 00:19:40,135 Punching the holes is kind of labor intensive, 562 00:19:40,266 --> 00:19:42,964 but the main thing is that I get a nice, tight fit. 563 00:19:43,094 --> 00:19:45,575 ♪ 564 00:19:45,706 --> 00:19:47,969 - I'm going to MIG weld the delam 565 00:19:48,099 --> 00:19:49,753 right there at the ricasso. 566 00:19:49,884 --> 00:19:52,016 - Britt over here on the flat platen 567 00:19:52,147 --> 00:19:53,366 of his grinder, 568 00:19:53,496 --> 00:19:55,368 just kind of working on cleaning up his welds. 569 00:19:55,498 --> 00:19:58,458 - The delam I'm dealing with is right at the top of the spine. 570 00:19:58,588 --> 00:20:00,808 So I wanna relieve every bit of the stress 571 00:20:00,938 --> 00:20:02,636 out of the spine of that knife that I can. 572 00:20:02,766 --> 00:20:05,421 So I'm gonna blue-back the knife 573 00:20:05,552 --> 00:20:07,075 so that the spine of that knife is 574 00:20:07,206 --> 00:20:09,730 as soft as it can possibly be. 575 00:20:09,860 --> 00:20:12,689 That's gonna allow that spine to absorb a lot more shock 576 00:20:12,820 --> 00:20:14,822 without damage. 577 00:20:14,952 --> 00:20:16,215 - One hour, bladesmiths. 578 00:20:16,345 --> 00:20:18,260 You have one hour remaining in the round. 579 00:20:18,391 --> 00:20:19,696 ♪ 580 00:20:19,827 --> 00:20:22,221 - I am working on my guard right now. 581 00:20:22,351 --> 00:20:23,918 Guards always take me a long time 582 00:20:24,048 --> 00:20:26,007 and I kind of suck at them, so I'm gonna try to get this done. 583 00:20:26,137 --> 00:20:27,530 It's gonna be ugly, but it's gonna be done. 584 00:20:27,661 --> 00:20:29,228 It's in. 585 00:20:29,358 --> 00:20:31,099 Handle material's gonna be this hose, 586 00:20:31,230 --> 00:20:33,406 cut to stack and glued. 587 00:20:33,536 --> 00:20:36,539 - As Chris stacks that handle, every five or six pieces, 588 00:20:36,670 --> 00:20:39,107 he's using that pipe to compress everything. 589 00:20:39,238 --> 00:20:41,196 So he's getting the compression with the glue as it dries. 590 00:20:41,327 --> 00:20:42,937 That's pretty smart. 591 00:20:43,067 --> 00:20:46,157 - I finish up the compression, trim off my tang. 592 00:20:46,288 --> 00:20:47,463 On to grinding. 593 00:20:47,594 --> 00:20:49,378 ♪ 594 00:20:49,509 --> 00:20:51,467 - When I'm clamping this, I'm gonna kind of overcompress. 595 00:20:51,598 --> 00:20:53,164 So that way, when I let it loose, 596 00:20:53,295 --> 00:20:55,428 it will come back a little bit. 597 00:20:55,558 --> 00:20:59,301 - It looks like Forest is actually using a work stick 598 00:20:59,432 --> 00:21:02,478 to slip down in between those clamps 599 00:21:02,609 --> 00:21:05,394 to peen on the tang 'cause you can't get a hammer in there. 600 00:21:05,525 --> 00:21:08,092 - Peening this over, I'm peening the end of the tang. 601 00:21:08,223 --> 00:21:11,400 And I set this thing on fire, and then that's a real pain. 602 00:21:11,531 --> 00:21:14,273 Now we go put the fire out. 603 00:21:14,403 --> 00:21:16,884 - Bladesmiths, you have less than 30 minutes remaining 604 00:21:17,014 --> 00:21:18,451 to finish your work. 605 00:21:18,581 --> 00:21:21,105 All of these guys opted to create their handles 606 00:21:21,236 --> 00:21:22,933 in an identical manner. 607 00:21:23,064 --> 00:21:27,024 They all put guards on, they're stacking just fire hose handles 608 00:21:27,155 --> 00:21:29,200 with mild steel butt caps. 609 00:21:29,331 --> 00:21:32,334 ♪ 610 00:21:32,465 --> 00:21:34,815 - Oh, boy. - Snap, my pommel cracked. 611 00:21:34,945 --> 00:21:36,512 Not good. 612 00:21:36,643 --> 00:21:39,167 I don't have enough time to make another butt cap. 613 00:21:39,298 --> 00:21:41,082 - It could actually let go in the testing. 614 00:21:41,212 --> 00:21:42,518 - I'm worried that the judges are gonna feel 615 00:21:42,649 --> 00:21:44,303 the pommel may come off. 616 00:21:44,433 --> 00:21:47,001 And if they feel it's unsafe to test, I'd be eliminated. 617 00:21:47,131 --> 00:21:50,134 ♪ 618 00:21:50,265 --> 00:21:52,354 Can't do anything about it. I've got my fingers crossed. 619 00:21:52,485 --> 00:21:53,747 It's too late to do anything about it. 620 00:21:53,877 --> 00:21:55,096 I don't have enough time to fix it. 621 00:21:55,226 --> 00:21:57,141 I think it'll hold to get through testing. 622 00:21:57,272 --> 00:21:59,187 As I'm grinding this material, 623 00:21:59,318 --> 00:22:01,320 I think if I can trim a little bit off of that butt cap, 624 00:22:01,450 --> 00:22:03,409 I might relieve some of the stress. 625 00:22:03,539 --> 00:22:04,888 And I'm hoping I've got enough of a pommel 626 00:22:05,019 --> 00:22:06,412 to hold that handle together. 627 00:22:06,542 --> 00:22:09,110 - Britt's got some issues with his but cap. 628 00:22:09,240 --> 00:22:10,372 - Oh. 629 00:22:10,503 --> 00:22:12,026 - And he's gluing the heck out of it. 630 00:22:12,156 --> 00:22:14,028 - People underestimate the amount of shock that comes back 631 00:22:14,158 --> 00:22:15,203 through the handle. 632 00:22:15,334 --> 00:22:16,465 I think there's a high probability 633 00:22:16,596 --> 00:22:17,945 that butt cap is gonna snap. 634 00:22:18,075 --> 00:22:20,382 - 20 minutes, bladesmiths. 635 00:22:20,513 --> 00:22:21,905 - Right now, I'm shaping up my handle. 636 00:22:22,036 --> 00:22:23,864 I'm gonna whittle it down and try to make a shape 637 00:22:23,994 --> 00:22:25,256 that fits my hand. 638 00:22:25,387 --> 00:22:26,606 The clock is not my friend. 639 00:22:26,736 --> 00:22:28,172 The material's not moving fast enough. 640 00:22:28,303 --> 00:22:29,957 I have to sacrifice 641 00:22:30,087 --> 00:22:32,133 what I normally would keep as standards... 642 00:22:32,263 --> 00:22:33,787 It's so small. 643 00:22:33,917 --> 00:22:35,615 In order to make sure it's a completed, strong knife. 644 00:22:35,745 --> 00:22:36,877 ♪ 645 00:22:37,007 --> 00:22:38,531 - I got my bevels finished. 646 00:22:38,661 --> 00:22:40,794 Now I'm ready to just finish this handle up. 647 00:22:40,924 --> 00:22:43,274 We're gonna just narrow this down, get this smoothed out. 648 00:22:43,405 --> 00:22:44,667 ♪ 649 00:22:44,798 --> 00:22:46,190 I'm rocking and rolling. 650 00:22:46,321 --> 00:22:47,931 - Five minutes, bladesmiths. 651 00:22:48,062 --> 00:22:49,890 - All I got left to do is just get it sharp. 652 00:22:50,020 --> 00:22:52,893 I'm going for what we call an appleseed edge 653 00:22:53,023 --> 00:22:54,547 which allows brutal chopping. 654 00:22:54,677 --> 00:22:56,200 It's also extremely sharp. 655 00:22:56,331 --> 00:22:57,637 In my opinion, this is the only kind of edge 656 00:22:57,767 --> 00:22:59,290 that's gonna get through this challenge, 657 00:22:59,421 --> 00:23:04,295 - Five, four, three, two, one. 658 00:23:04,426 --> 00:23:06,472 Bladesmiths, stop all that sharpening. 659 00:23:06,602 --> 00:23:08,561 This second round of competition is over. 660 00:23:08,691 --> 00:23:10,171 Good job. 661 00:23:10,301 --> 00:23:12,608 - My blade may not be quite as pretty, 662 00:23:12,739 --> 00:23:14,523 but I'm hoping that that serves its purpose 663 00:23:14,654 --> 00:23:15,437 as designed. 664 00:23:15,568 --> 00:23:17,744 ♪ 665 00:23:17,874 --> 00:23:19,876 - Bladesmiths, welcome to the strength test, 666 00:23:20,007 --> 00:23:21,225 the burning wood chop. 667 00:23:21,356 --> 00:23:22,662 ♪ 668 00:23:22,792 --> 00:23:24,011 To test the strength of your edge, 669 00:23:24,141 --> 00:23:25,882 I'll be chopping them into this burning wood. 670 00:23:26,013 --> 00:23:27,841 Remember, this test is all about what the wood does 671 00:23:27,971 --> 00:23:29,886 to your knives, and not what your knives do to the wood. 672 00:23:30,017 --> 00:23:31,584 Forest, you're up first. How are you feeling? 673 00:23:31,714 --> 00:23:33,586 - Nervous, but I'm ready to go. - All right. 674 00:23:33,716 --> 00:23:35,979 ♪ 675 00:23:36,110 --> 00:23:38,373 - Number one thing that could go wrong with this blade, 676 00:23:38,504 --> 00:23:40,680 I'm concerned about catastrophic failure. 677 00:23:40,810 --> 00:23:43,073 Obviously, that's gonna knock me out of the competition. 678 00:23:43,204 --> 00:23:50,124 ♪ 679 00:24:01,701 --> 00:24:03,050 - Well, Forest, first thing's first, 680 00:24:03,180 --> 00:24:04,660 your edge held up great. 681 00:24:04,791 --> 00:24:07,620 I'm still seeing some delaminations from earlier, 682 00:24:07,750 --> 00:24:09,622 but it didn't cause any structural issues 683 00:24:09,752 --> 00:24:10,753 in this blade at all. 684 00:24:10,884 --> 00:24:13,103 Well done. - Awesome, thank you. 685 00:24:13,234 --> 00:24:14,670 - Chris, you're up next. Are you ready? 686 00:24:14,801 --> 00:24:15,845 - I am. 687 00:24:15,976 --> 00:24:17,847 ♪ 688 00:24:17,978 --> 00:24:19,109 Coming into this test, 689 00:24:19,240 --> 00:24:21,895 I feel very strong about my steel. 690 00:24:22,025 --> 00:24:24,027 My only concerns are the handle 691 00:24:24,158 --> 00:24:25,115 and where I didn't weld. 692 00:24:25,246 --> 00:24:32,122 ♪ 693 00:24:37,954 --> 00:24:40,653 - Oh, man. - That weld. 694 00:24:40,783 --> 00:24:46,180 ♪ 695 00:24:46,310 --> 00:24:48,704 [exhales] 696 00:24:48,835 --> 00:24:51,054 - Well, Chris, we got an issue here. 697 00:24:51,185 --> 00:24:52,491 ♪ 698 00:24:52,621 --> 00:24:53,622 This is the spot, of course, 699 00:24:53,753 --> 00:24:55,711 where you welded your mild steel tang 700 00:24:55,842 --> 00:24:57,713 onto your existing tang. 701 00:24:57,844 --> 00:25:00,455 I just see the slightest of penetration in that weld. 702 00:25:00,586 --> 00:25:02,326 I mean, it's like it just came in from the insides 703 00:25:02,457 --> 00:25:03,719 and just didn't get deep enough. 704 00:25:03,850 --> 00:25:09,420 ♪ 705 00:25:09,551 --> 00:25:10,987 - Chris, your blade has suffered 706 00:25:11,118 --> 00:25:13,903 a catastrophic failure of the handle on the fifth strike. 707 00:25:14,034 --> 00:25:16,079 But that doesn't mean that you're out of this competition. 708 00:25:16,210 --> 00:25:19,866 If Britt's blade goes bad before five hits, 709 00:25:19,996 --> 00:25:21,737 you'll be moving forward in this competition. 710 00:25:21,868 --> 00:25:24,523 Britt, how you feeling? - Let her rip, tater chip. 711 00:25:24,653 --> 00:25:25,611 - Ben. 712 00:25:25,741 --> 00:25:27,351 ♪ 713 00:25:27,482 --> 00:25:29,702 - I know my blade's gotta survive five strikes. 714 00:25:29,832 --> 00:25:31,921 I'm still concerned about my butt cap. 715 00:25:32,052 --> 00:25:33,923 Man, I really hope my blade holds together. 716 00:25:34,054 --> 00:25:43,237 ♪ 717 00:25:53,116 --> 00:25:55,118 - Gentleme- Good job, man. 718 00:25:55,249 --> 00:25:57,381 - Well, Britt, you're all in one piece. 719 00:25:57,512 --> 00:25:58,861 The edge itself, 720 00:25:58,992 --> 00:26:01,298 for being such a fine grind on your knife here, 721 00:26:01,429 --> 00:26:02,865 it held up nicely. 722 00:26:02,996 --> 00:26:04,563 And I was sure this butt cap was gonna come off. 723 00:26:04,693 --> 00:26:06,782 - I was seriously concerned it was gonna come off myself. 724 00:26:06,913 --> 00:26:08,088 - [laughs] Well done. 725 00:26:08,218 --> 00:26:09,263 - Thank you, sir. 726 00:26:09,393 --> 00:26:11,744 ♪ 727 00:26:11,874 --> 00:26:13,572 - All right, bladesmiths. 728 00:26:13,702 --> 00:26:15,835 What we have here is two blades that can continue with testing. 729 00:26:15,965 --> 00:26:18,402 Chris, unfortunately, your blade cannot. 730 00:26:18,533 --> 00:26:19,969 For that reason, come on over. 731 00:26:20,100 --> 00:26:21,710 ♪ 732 00:26:21,841 --> 00:26:23,364 - I do feel like I proved what I wanted to prove 733 00:26:23,494 --> 00:26:24,670 by coming here. 734 00:26:24,800 --> 00:26:26,019 Thank you, sir. - Good job, man. 735 00:26:26,149 --> 00:26:28,325 - I made a solid blade, no damage to it. 736 00:26:28,456 --> 00:26:30,066 The only issue was the handle. 737 00:26:30,197 --> 00:26:31,764 I may not be the "Forged in Fire" champion, 738 00:26:31,894 --> 00:26:33,374 but I do feel 739 00:26:33,504 --> 00:26:34,984 that I did my fellow first responders justice. 740 00:26:35,115 --> 00:26:38,161 ♪ 741 00:26:38,292 --> 00:26:39,902 - Britt, Forest, congratulations. 742 00:26:40,033 --> 00:26:42,862 The strength of your tactical blades has landed you 743 00:26:42,992 --> 00:26:44,951 in the third and final round of this competition, 744 00:26:45,081 --> 00:26:48,432 which means that you're both four short forging days shy 745 00:26:48,563 --> 00:26:49,999 of the title of "Forged in Fire" champion 746 00:26:50,130 --> 00:26:51,827 and that check for $10,000. 747 00:26:51,958 --> 00:26:54,308 All you need to do now is make one of these. 748 00:26:54,438 --> 00:26:58,094 ♪ 749 00:26:58,225 --> 00:26:59,356 A Halligan bar. 750 00:26:59,487 --> 00:27:00,357 ♪ 751 00:27:00,488 --> 00:27:01,750 - [laughs] 752 00:27:01,881 --> 00:27:03,970 - It is an iconic rescue tool, 753 00:27:04,100 --> 00:27:08,278 and here to tell you more about it is Captain Brian Olith. 754 00:27:08,409 --> 00:27:10,280 - The Halligan bar, to the modern fire service, 755 00:27:10,411 --> 00:27:12,239 is the multipurpose tool. 756 00:27:12,369 --> 00:27:14,502 It is probably the most important tool 757 00:27:14,633 --> 00:27:16,112 that's carried on the fire truck 758 00:27:16,243 --> 00:27:18,593 besides water and hose and the firefighters themselves. 759 00:27:18,724 --> 00:27:20,290 ♪ 760 00:27:20,421 --> 00:27:22,205 It was originally designed by a deputy chief 761 00:27:22,336 --> 00:27:24,294 in New York City in 1948. 762 00:27:24,425 --> 00:27:26,906 The primary purpose was to force entry through doors. 763 00:27:27,036 --> 00:27:27,994 ♪ 764 00:27:28,124 --> 00:27:29,822 On one end, there's a fork. 765 00:27:29,952 --> 00:27:32,999 On the other end, there's an adze and a metal pike. 766 00:27:33,129 --> 00:27:36,480 You take the tool, and you put it in between the door frame 767 00:27:36,611 --> 00:27:38,352 and the door itself, 768 00:27:38,482 --> 00:27:40,789 and you could actually wedge the fork and force the door. 769 00:27:40,920 --> 00:27:43,226 The primary striking surfaces of the tool are 770 00:27:43,357 --> 00:27:45,968 the adze itself and the back of the adze. 771 00:27:46,099 --> 00:27:48,318 So this part of the tool has to be extremely strong 772 00:27:48,449 --> 00:27:50,233 'cause it's gonna be taking a full force strike 773 00:27:50,364 --> 00:27:52,235 with an eight-pound ax. 774 00:27:52,366 --> 00:27:53,236 - All right, gentlemen. 775 00:27:53,367 --> 00:27:55,151 Your Halligan bars must fall 776 00:27:55,282 --> 00:27:57,284 within the following parameters. 777 00:27:57,414 --> 00:28:00,156 The length should be between 28 and 30 inches. 778 00:28:00,287 --> 00:28:02,681 The length of the forks, pike, and the adze 779 00:28:02,811 --> 00:28:04,334 should be six inches. 780 00:28:04,465 --> 00:28:06,946 - It's a complex tool, so it's not something 781 00:28:07,076 --> 00:28:09,905 you can just forge in the shape of a blade. 782 00:28:10,036 --> 00:28:11,907 There's a lot of different angles, 783 00:28:12,038 --> 00:28:13,953 and everything all has to be functional. 784 00:28:14,083 --> 00:28:15,868 So it's gonna be a very difficult build. 785 00:28:15,998 --> 00:28:17,608 - Gentlemen, you have four days at your home forges 786 00:28:17,739 --> 00:28:19,132 in which to complete this challenge. 787 00:28:19,262 --> 00:28:21,351 At the end of that time, we will be testing 788 00:28:21,482 --> 00:28:22,918 your Halligan bars, and then one of you 789 00:28:23,049 --> 00:28:25,268 will be awarded the title of "Forged in Fire" champion 790 00:28:25,399 --> 00:28:27,967 and be given a check for $10,000. 791 00:28:28,097 --> 00:28:29,882 Good luck. We'll see you in four days. 792 00:28:30,012 --> 00:28:31,318 - Good luck, brother. - Right on. 793 00:28:31,448 --> 00:28:35,148 ♪ 794 00:28:35,278 --> 00:28:36,453 - We're at the beginning of day one. 795 00:28:36,584 --> 00:28:37,672 Looking forward to representing 796 00:28:37,803 --> 00:28:39,195 the Border Patrol. 797 00:28:39,326 --> 00:28:40,980 I can't wait to get started on this Halligan tool. 798 00:28:41,110 --> 00:28:42,590 I'm going to utilize the quarter band. 799 00:28:42,721 --> 00:28:43,983 ♪ 800 00:28:44,113 --> 00:28:45,375 I'm gonna make a couple of initial cuts 801 00:28:45,506 --> 00:28:46,637 and isolate some material. 802 00:28:46,768 --> 00:28:48,030 Let's get it hot. 803 00:28:48,161 --> 00:28:49,249 ♪ 804 00:28:49,379 --> 00:28:50,946 One side's gonna be the adze, 805 00:28:51,077 --> 00:28:52,469 and one side is gonna be a spike. 806 00:28:52,600 --> 00:28:54,036 [groans] 807 00:28:54,167 --> 00:28:55,516 What the tool needs to do, 808 00:28:55,646 --> 00:28:57,387 there needs to be a certain amount of mass 809 00:28:57,518 --> 00:29:00,260 for the ax to strike it. 810 00:29:00,390 --> 00:29:02,697 Also, there's a lot of wrenching and twisting, 811 00:29:02,828 --> 00:29:04,786 so there needs to be some mass to support that. 812 00:29:04,917 --> 00:29:06,396 ♪ 813 00:29:06,527 --> 00:29:08,355 It's the end of day one. Today was challenging. 814 00:29:08,485 --> 00:29:10,574 I think the build is still going pretty well. 815 00:29:10,705 --> 00:29:12,098 We'll just have to see what tomorrow beings. 816 00:29:12,228 --> 00:29:13,708 Ain't we having fun now? 817 00:29:13,839 --> 00:29:16,929 ♪ 818 00:29:17,059 --> 00:29:18,713 - Today, I'm gonna start forging the Halligan. 819 00:29:18,844 --> 00:29:21,281 I'm gonna start at the fork end and just work my way back. 820 00:29:21,411 --> 00:29:22,717 ♪ 821 00:29:22,848 --> 00:29:24,806 My plan for construction on this Halligan 822 00:29:24,937 --> 00:29:27,374 is forge-weld the Damascus billet. 823 00:29:27,504 --> 00:29:29,245 Not only is that gonna add strength, 824 00:29:29,376 --> 00:29:31,726 but it will lend a considerable amount 825 00:29:31,857 --> 00:29:33,380 of aesthetic value to this. 826 00:29:33,510 --> 00:29:35,599 [sighs] Is this enough steel? 827 00:29:35,730 --> 00:29:36,818 Yeah. 828 00:29:36,949 --> 00:29:38,341 ♪ 829 00:29:38,472 --> 00:29:41,431 The pressure of being a retired fireman, 830 00:29:41,562 --> 00:29:44,304 and being tasked with making the very first Halligan 831 00:29:44,434 --> 00:29:47,568 on "Forged in Fire," that situation is not lost on me 832 00:29:47,698 --> 00:29:49,352 by any means. 833 00:29:49,483 --> 00:29:50,963 If I think about it too much, 834 00:29:51,093 --> 00:29:53,095 I could probably put a lot of pressure on myself. 835 00:29:53,226 --> 00:29:56,185 But what I have control over is my design, 836 00:29:56,316 --> 00:29:58,579 and I'm gonna do it the best that I can. 837 00:29:58,709 --> 00:30:00,146 And this day is over. 838 00:30:00,276 --> 00:30:01,321 ♪ 839 00:30:01,451 --> 00:30:02,801 - Beginning of day two. 840 00:30:02,931 --> 00:30:05,194 Let's get that steel hot and beat the hell out of it. 841 00:30:05,325 --> 00:30:06,630 What we're gonna do today 842 00:30:06,761 --> 00:30:08,589 is we're gonna work on forming the adze. 843 00:30:08,719 --> 00:30:09,851 We're gonna stretch out the handle. 844 00:30:09,982 --> 00:30:11,722 ♪ 845 00:30:11,853 --> 00:30:13,637 Right now, we're just getting that handle stretched out 846 00:30:13,768 --> 00:30:15,291 to give us our length. 847 00:30:15,422 --> 00:30:17,032 For firefighters, you're gonna want something 848 00:30:17,163 --> 00:30:19,208 with some heft to it to grip it. 849 00:30:19,339 --> 00:30:22,342 So for now, I'm just coming in here and squashing my corners. 850 00:30:22,472 --> 00:30:23,517 ♪ 851 00:30:23,647 --> 00:30:25,780 To give it an octagonal shape. 852 00:30:25,911 --> 00:30:27,086 ♪ 853 00:30:27,216 --> 00:30:29,784 It's really looking like it's supposed to. 854 00:30:29,915 --> 00:30:31,655 I'm gonna do some grinding, and clean up, 855 00:30:31,786 --> 00:30:33,048 and make sure I don't have any cold shuts. 856 00:30:33,179 --> 00:30:34,354 ♪ 857 00:30:34,484 --> 00:30:35,877 I got a lot done today. 858 00:30:36,008 --> 00:30:37,748 I'm down to forging out the forks 859 00:30:37,879 --> 00:30:38,837 and a little bit of straightening, 860 00:30:38,967 --> 00:30:40,099 and then on to heat treat. 861 00:30:40,229 --> 00:30:42,579 Really feeling good about it. Whoo-hoo! 862 00:30:42,710 --> 00:30:44,190 Life is good. Life is good. 863 00:30:44,320 --> 00:30:45,495 ♪ 864 00:30:45,626 --> 00:30:47,367 - Day three. 865 00:30:47,497 --> 00:30:49,151 I'm ready to get this thing forged and get it quenched. 866 00:30:49,282 --> 00:30:50,631 ♪ 867 00:30:50,761 --> 00:30:53,503 Get my forks pretty well shaped up. 868 00:30:53,634 --> 00:30:56,637 I start forging that pike out and it's looking good. 869 00:30:56,767 --> 00:30:58,987 So now it's time to drip the hole for the pike. 870 00:30:59,118 --> 00:30:59,988 Here we go. 871 00:31:00,119 --> 00:31:01,816 ♪ 872 00:31:01,947 --> 00:31:03,600 All right. That's a biggie. 873 00:31:03,731 --> 00:31:06,429 Now all we have to do is get the adze into place. 874 00:31:06,560 --> 00:31:07,691 ♪ 875 00:31:07,822 --> 00:31:09,432 And we're ready to quench. 876 00:31:09,563 --> 00:31:10,694 ♪ 877 00:31:10,825 --> 00:31:12,435 I get things up to heat. 878 00:31:12,566 --> 00:31:14,089 I go ahead, put it in the quench tank. 879 00:31:14,220 --> 00:31:15,395 ♪ 880 00:31:15,525 --> 00:31:17,484 And I've got too little oil. 881 00:31:17,614 --> 00:31:19,007 Oh, that's not good. 882 00:31:19,138 --> 00:31:21,009 So now, I've got an incomplete quench. 883 00:31:21,140 --> 00:31:22,445 ♪ 884 00:31:22,576 --> 00:31:24,230 The only part that's really not hard 885 00:31:24,360 --> 00:31:27,581 is the really important part like the adze and the pike. 886 00:31:27,711 --> 00:31:29,713 I'm gonna requench on that. 887 00:31:29,844 --> 00:31:31,890 Every time that we do this, we're just running 888 00:31:32,020 --> 00:31:34,544 the risk of other failures, more stress in the tool. 889 00:31:34,675 --> 00:31:37,504 Everything's riding on this being right. 890 00:31:37,634 --> 00:31:39,114 If this doesn't work, I'm screwed. 891 00:31:39,245 --> 00:31:45,555 ♪ 892 00:31:45,686 --> 00:31:46,774 Much better. 893 00:31:46,905 --> 00:31:48,645 It's actually a really good quench. 894 00:31:48,776 --> 00:31:50,212 I'm happy. 895 00:31:50,343 --> 00:31:51,387 It's a good thing I'm retired, 'cause I don't know 896 00:31:51,518 --> 00:31:53,912 that I ever want to see a Halligan again. 897 00:31:54,042 --> 00:31:55,478 - Beginning of day four. 898 00:31:55,609 --> 00:31:58,394 Today we're gonna forge out the forks. 899 00:31:58,525 --> 00:32:00,744 And there you have it, boys and girls. 900 00:32:00,875 --> 00:32:02,224 [hammer tapping, tool buzzing] 901 00:32:02,355 --> 00:32:03,399 That's heat-treated. 902 00:32:03,530 --> 00:32:04,748 This is, hands-down, 903 00:32:04,879 --> 00:32:07,664 the largest tool I've ever quenched. 904 00:32:07,795 --> 00:32:09,710 So what we're gonna end up doing is, 905 00:32:09,840 --> 00:32:11,190 we're gonna heat-treat the front half, 906 00:32:11,320 --> 00:32:14,454 flip it around, heat-treat the second half. 907 00:32:14,584 --> 00:32:15,846 Let's quench this beast. 908 00:32:15,977 --> 00:32:19,154 ♪ 909 00:32:19,285 --> 00:32:21,461 She's straight. I see no cracks. 910 00:32:21,591 --> 00:32:22,853 Let's quench the other half. 911 00:32:22,984 --> 00:32:24,899 Three, two, one. 912 00:32:25,030 --> 00:32:27,032 ♪ 913 00:32:27,162 --> 00:32:29,556 We have a successful quench. 914 00:32:29,686 --> 00:32:30,644 ♪ 915 00:32:30,774 --> 00:32:32,951 So what we're gonna do 916 00:32:33,081 --> 00:32:35,170 is simulate a breach. 917 00:32:35,301 --> 00:32:38,434 [wood cracking] 918 00:32:38,565 --> 00:32:39,653 I'd say it works. 919 00:32:39,783 --> 00:32:41,307 - So day four. 920 00:32:41,437 --> 00:32:44,266 I'm just going to do some final grinding, 921 00:32:44,397 --> 00:32:49,271 basically get it all cleaned up and ready for show. 922 00:32:49,402 --> 00:32:53,145 I'm confident in it, but it is kind of lightweight. 923 00:32:53,275 --> 00:32:55,756 Just gonna test this out. 924 00:32:55,886 --> 00:32:58,324 That's about all the testing I want to do. 925 00:32:58,454 --> 00:32:59,760 [laughs] 'Cause I'm kind of chicken. 926 00:32:59,890 --> 00:33:02,676 [dramatic music] 927 00:33:02,806 --> 00:33:08,769 ♪ 928 00:33:10,727 --> 00:33:11,772 Britt, Forest, 929 00:33:11,902 --> 00:33:13,730 welcome back, and welcome to 930 00:33:13,861 --> 00:33:16,255 the Stamford Fire training center. 931 00:33:16,385 --> 00:33:18,213 You guys have had four days at your home forges 932 00:33:18,344 --> 00:33:20,128 to work on your Halligan bars. 933 00:33:20,259 --> 00:33:21,347 Britt, how did it go? 934 00:33:21,477 --> 00:33:22,261 - Went well. 935 00:33:22,391 --> 00:33:24,132 ♪ 936 00:33:24,263 --> 00:33:25,742 It's 1045 tool steel. 937 00:33:25,873 --> 00:33:27,266 Forged it from one piece. 938 00:33:27,396 --> 00:33:29,746 Both of the tool ends were all hand-hammered. 939 00:33:29,877 --> 00:33:30,791 Looking forward to see what it does. 940 00:33:30,921 --> 00:33:32,445 - Forest, how'd it go for you? 941 00:33:32,575 --> 00:33:35,100 - I'm happy with the design and how it all came out. 942 00:33:35,230 --> 00:33:36,971 ♪ 943 00:33:37,102 --> 00:33:39,060 I've used 1045 944 00:33:39,191 --> 00:33:42,977 and then with a six-layered Damascus on my top and bottom, 945 00:33:43,108 --> 00:33:46,328 so it's a Damascus sandwich from end to end. 946 00:33:46,459 --> 00:33:49,070 - Gentlemen, these are very special rescue tools, 947 00:33:49,201 --> 00:33:50,637 and we're putting them through the paces today 948 00:33:50,767 --> 00:33:52,160 here at the training center. 949 00:33:52,291 --> 00:33:54,293 Your weapons will be put through two 950 00:33:54,423 --> 00:33:57,165 very, very staunch rescue tests. 951 00:33:57,296 --> 00:33:59,037 Up first is Doug. 952 00:33:59,167 --> 00:34:02,127 ♪ 953 00:34:02,257 --> 00:34:05,782 - Bladesmiths, welcome to the car crash extraction test. 954 00:34:05,913 --> 00:34:07,480 ♪ 955 00:34:07,610 --> 00:34:09,090 To test your Halligan bars, 956 00:34:09,221 --> 00:34:10,526 I'm gonna take your Halligan bar 957 00:34:10,657 --> 00:34:13,964 and try to rescue this dummy inside this crashed car. 958 00:34:14,095 --> 00:34:17,707 Now, this is all about how well your Halligan bars perform. 959 00:34:17,838 --> 00:34:21,450 It's time to find out if your Halligan bars will rescue. 960 00:34:21,581 --> 00:34:23,365 To test your Halligan bars, 961 00:34:23,496 --> 00:34:26,151 I'd like to introduce firefighters Jim and Carl. 962 00:34:26,281 --> 00:34:27,935 ♪ 963 00:34:28,066 --> 00:34:29,197 Welcome, gentlemen. 964 00:34:29,328 --> 00:34:30,938 Britt, you're up first. You ready? 965 00:34:31,069 --> 00:34:32,070 - Grip and rip it. 966 00:34:32,200 --> 00:34:34,028 - All right, let's do this. 967 00:34:34,159 --> 00:34:35,812 - My biggest concern coming into the testing 968 00:34:35,943 --> 00:34:37,553 is the thickness of my adze. 969 00:34:37,684 --> 00:34:39,555 It's an area that's gonna get a lot of pressure. 970 00:34:39,686 --> 00:34:41,253 And that prying movement could expose 971 00:34:41,383 --> 00:34:42,558 anything where I might have done something wrong 972 00:34:42,689 --> 00:34:43,820 in my heat-treat, 973 00:34:43,951 --> 00:34:45,779 so as long as I nailed my heat-treat, 974 00:34:45,909 --> 00:34:47,259 I'm not gonna have any issues. 975 00:34:47,389 --> 00:34:50,479 ♪ 976 00:34:50,610 --> 00:34:51,524 [air hisses] 977 00:34:51,654 --> 00:34:52,742 ♪ 978 00:34:52,873 --> 00:34:53,917 [air hisses] 979 00:34:54,048 --> 00:34:56,094 ♪ 980 00:34:56,224 --> 00:34:57,007 [metallic clank] - Hit. 981 00:34:57,138 --> 00:34:58,574 Yep. 982 00:34:58,705 --> 00:35:02,187 [metallic creaking] 983 00:35:02,317 --> 00:35:04,798 ♪ 984 00:35:04,928 --> 00:35:05,886 Hit. 985 00:35:06,016 --> 00:35:07,148 [metallic thud] Hit. 986 00:35:07,279 --> 00:35:08,932 [metallic thud, creaking] 987 00:35:09,063 --> 00:35:11,979 ♪ 988 00:35:12,110 --> 00:35:14,068 - Nice. 989 00:35:14,199 --> 00:35:19,769 [glass shatters] 990 00:35:19,900 --> 00:35:21,206 - All right, gentlemen, what do you think? 991 00:35:21,336 --> 00:35:22,946 - The weight is a little heavy. 992 00:35:23,077 --> 00:35:24,296 The spike worked very well. 993 00:35:24,426 --> 00:35:25,427 ♪ 994 00:35:25,558 --> 00:35:26,733 - All right, Britt, 995 00:35:26,863 --> 00:35:27,777 let's talk about your Halligan bar here, 996 00:35:27,908 --> 00:35:29,736 based on the firefighters' feedback. 997 00:35:29,866 --> 00:35:33,261 First up, the bar: it's a little bit heavier. 998 00:35:33,392 --> 00:35:34,958 But it's manageable. 999 00:35:35,089 --> 00:35:37,135 When it comes to your spike and your adze over here, 1000 00:35:37,265 --> 00:35:40,050 they function quite well and they got the job done. 1001 00:35:40,181 --> 00:35:42,270 Overall, sir, it will rescue. 1002 00:35:42,401 --> 00:35:43,967 - Thank you, sir. 1003 00:35:44,098 --> 00:35:45,752 - Okay, Forest, your turn, sir. You ready? 1004 00:35:45,882 --> 00:35:47,710 - Well, we didn't get dressed up for nothing. 1005 00:35:47,841 --> 00:35:48,624 - [laughing] All right. 1006 00:35:48,755 --> 00:35:49,843 Let's do it. 1007 00:35:49,973 --> 00:35:51,627 - Man, I'm nervous. 1008 00:35:51,758 --> 00:35:53,238 We're gonna really test this Halligan. 1009 00:35:53,368 --> 00:35:55,544 We've got firefighting professionals 1010 00:35:55,675 --> 00:35:57,459 that are well-versed in utilizing 1011 00:35:57,590 --> 00:36:00,070 the ways that would be typical to use this. 1012 00:36:00,201 --> 00:36:03,291 My biggest concern is a possible structural failure 1013 00:36:03,422 --> 00:36:05,206 'cause it's a little on the lighter side. 1014 00:36:05,337 --> 00:36:07,426 I just hope that it's strong enough to hold up. 1015 00:36:07,556 --> 00:36:08,427 - Clear. 1016 00:36:08,557 --> 00:36:12,822 ♪ 1017 00:36:12,953 --> 00:36:13,910 [air hisses] 1018 00:36:14,041 --> 00:36:15,085 ♪ 1019 00:36:15,216 --> 00:36:19,089 [air hissing] 1020 00:36:19,220 --> 00:36:20,395 ♪ 1021 00:36:20,526 --> 00:36:21,962 Hit. 1022 00:36:22,092 --> 00:36:23,006 [metallic thud] Hit. 1023 00:36:23,137 --> 00:36:25,531 [metallic thud] Hit. 1024 00:36:25,661 --> 00:36:27,489 Hit. [metallic thud] 1025 00:36:27,620 --> 00:36:28,621 Hit again. 1026 00:36:28,751 --> 00:36:29,883 ♪ 1027 00:36:30,013 --> 00:36:30,840 [metallic thud] Hit. 1028 00:36:30,971 --> 00:36:32,146 [metallic thud] 1029 00:36:32,277 --> 00:36:33,321 [metallic creaks] 1030 00:36:33,452 --> 00:36:36,019 ♪ 1031 00:36:36,150 --> 00:36:37,107 [metallic thud] Hit. 1032 00:36:37,238 --> 00:36:38,239 [metallic thud] 1033 00:36:38,370 --> 00:36:40,633 [metallic creaking] 1034 00:36:40,763 --> 00:36:42,635 [glass shatters] 1035 00:36:42,765 --> 00:36:44,332 [glass rattling] 1036 00:36:44,463 --> 00:36:45,768 - Damn. 1037 00:36:45,899 --> 00:36:46,769 - The striking surface is a little bit off. 1038 00:36:46,900 --> 00:36:47,901 - Striking. 1039 00:36:48,031 --> 00:36:49,294 - Yeah, 'cause it's curved here. 1040 00:36:49,424 --> 00:36:51,209 ♪ 1041 00:36:51,339 --> 00:36:53,776 - All right, Forest, let's talk about your Halligan bar here. 1042 00:36:53,907 --> 00:36:55,996 First up, it's a lighter weight, 1043 00:36:56,126 --> 00:36:57,998 so it's easier to carry. 1044 00:36:58,128 --> 00:36:59,608 Now, the adze over here 1045 00:36:59,739 --> 00:37:02,132 did not penetrate nicely inside, 1046 00:37:02,263 --> 00:37:03,656 and the reason for that is, 1047 00:37:03,786 --> 00:37:05,397 you don't have a flat surface here. 1048 00:37:05,527 --> 00:37:07,225 Not having a flat surface here, 1049 00:37:07,355 --> 00:37:09,966 when you're making impact, it kind of shears off the side. 1050 00:37:10,097 --> 00:37:11,838 But it was effective, it worked, 1051 00:37:11,968 --> 00:37:13,361 and more importantly, 1052 00:37:13,492 --> 00:37:14,493 it will rescue. 1053 00:37:14,623 --> 00:37:17,452 ♪ 1054 00:37:17,583 --> 00:37:19,106 - Congratulations, gentlemen. 1055 00:37:19,237 --> 00:37:21,456 Your Halligan bars have passed our first test. 1056 00:37:21,587 --> 00:37:23,153 So now we've turned up the heat. 1057 00:37:23,284 --> 00:37:24,851 This is our flaming tower test. 1058 00:37:24,981 --> 00:37:28,594 ♪ 1059 00:37:28,724 --> 00:37:30,030 Now, to test your Halligan bars, 1060 00:37:30,160 --> 00:37:32,032 firefighter Steve and Captain John 1061 00:37:32,162 --> 00:37:33,381 are going to take them 1062 00:37:33,512 --> 00:37:35,470 and break through this training door. 1063 00:37:35,601 --> 00:37:36,906 Once they're through that door, 1064 00:37:37,037 --> 00:37:38,256 they'll go up three flights of stairs, 1065 00:37:38,386 --> 00:37:39,605 use your Halligan tool again 1066 00:37:39,735 --> 00:37:42,564 to bust out that window to assist in the rescue. 1067 00:37:42,695 --> 00:37:43,870 Now, no one really knows 1068 00:37:44,000 --> 00:37:45,393 what's gonna happen in a rescue situation, 1069 00:37:45,524 --> 00:37:47,743 so to test that Halligan tool one more time, 1070 00:37:47,874 --> 00:37:49,919 we're gonna drop it from that three-story window. 1071 00:37:50,050 --> 00:37:51,225 - Awesome. 1072 00:37:51,356 --> 00:37:52,400 - All right, Britt, are you ready? 1073 00:37:52,531 --> 00:37:53,445 - Let's break it. 1074 00:37:53,575 --> 00:37:54,533 - [laughs] 1075 00:37:54,663 --> 00:38:00,103 ♪ 1076 00:38:00,234 --> 00:38:05,065 [metallic thudding] 1077 00:38:05,195 --> 00:38:06,849 - Hit. [metallic thud] 1078 00:38:06,980 --> 00:38:07,850 Hit. [metallic thud] 1079 00:38:07,981 --> 00:38:08,764 Hit. [metallic thud] 1080 00:38:08,895 --> 00:38:10,070 [metallic thuds] 1081 00:38:10,200 --> 00:38:13,682 [metallic creaking] 1082 00:38:13,813 --> 00:38:17,643 ♪ 1083 00:38:17,773 --> 00:38:19,775 [glass shatters] 1084 00:38:19,906 --> 00:38:21,647 [loud thudding] 1085 00:38:21,777 --> 00:38:22,996 [window crashes] 1086 00:38:23,126 --> 00:38:26,652 ♪ 1087 00:38:26,782 --> 00:38:28,784 [metallic clanging] 1088 00:38:28,915 --> 00:38:29,785 - Oh, yes. 1089 00:38:29,916 --> 00:38:31,918 - [laughs] 1090 00:38:32,048 --> 00:38:33,528 - The biggest thing was the forks. 1091 00:38:33,659 --> 00:38:34,573 They were a little too thick. 1092 00:38:34,703 --> 00:38:36,488 ♪ 1093 00:38:36,618 --> 00:38:39,229 - So, Britt, first off, your adze worked very nicely. 1094 00:38:39,360 --> 00:38:41,231 But the width of your forks was an issue 1095 00:38:41,362 --> 00:38:43,321 since they're so thick right here. 1096 00:38:43,451 --> 00:38:44,583 Captain had a hard time 1097 00:38:44,713 --> 00:38:46,062 getting that into that door jamb. 1098 00:38:46,193 --> 00:38:47,455 When every second counts, 1099 00:38:47,586 --> 00:38:49,414 you want that to pass right through. 1100 00:38:49,544 --> 00:38:52,765 But overall, performed well, took the fall like a champ. 1101 00:38:52,895 --> 00:38:53,809 Good job. 1102 00:38:53,940 --> 00:38:54,984 - Thank you, sir. 1103 00:38:55,115 --> 00:38:55,898 - All right, Forest, you're up now. 1104 00:38:56,029 --> 00:38:56,899 You ready? 1105 00:38:57,030 --> 00:38:58,074 - Yes, sir. 1106 00:38:58,205 --> 00:38:59,511 ♪ 1107 00:38:59,641 --> 00:39:00,860 - Captain, it's all yours. 1108 00:39:00,990 --> 00:39:03,297 ♪ 1109 00:39:03,428 --> 00:39:07,127 [metallic thudding] 1110 00:39:07,257 --> 00:39:08,302 - Hit. [metallic thud] 1111 00:39:08,433 --> 00:39:09,390 Hit. [metallic thud] 1112 00:39:09,521 --> 00:39:11,131 Hit. 1113 00:39:11,261 --> 00:39:13,829 [metallic thud] 1114 00:39:13,960 --> 00:39:14,743 Hit. [metallic thud] 1115 00:39:14,874 --> 00:39:16,136 Good. 1116 00:39:16,266 --> 00:39:18,312 [metallic creak] 1117 00:39:18,443 --> 00:39:21,707 ♪ 1118 00:39:21,837 --> 00:39:22,664 [air tank hissing] 1119 00:39:22,795 --> 00:39:23,665 [loud thud] 1120 00:39:23,796 --> 00:39:24,797 [glass shatters] 1121 00:39:24,927 --> 00:39:25,972 [loud thudding] 1122 00:39:26,102 --> 00:39:27,408 [window crashes] 1123 00:39:27,539 --> 00:39:30,063 ♪ 1124 00:39:30,193 --> 00:39:31,456 [metallic clanging] 1125 00:39:31,586 --> 00:39:35,329 ♪ 1126 00:39:35,460 --> 00:39:36,809 - This hitting surface could be a little bit bigger. 1127 00:39:36,939 --> 00:39:38,376 - Right. 1128 00:39:38,506 --> 00:39:41,291 - My guys could tend to miss it a little bit. 1129 00:39:41,422 --> 00:39:44,294 - So, Forest, right off, the Damascus was a nice touch. 1130 00:39:44,425 --> 00:39:46,775 The forks got into that door really easily, 1131 00:39:46,906 --> 00:39:50,997 but this corner should be sort of a 90-degree with flats. 1132 00:39:51,127 --> 00:39:53,695 The ax kind of slid off a few times, 1133 00:39:53,826 --> 00:39:56,219 and you really want a good driving surface on this. 1134 00:39:56,350 --> 00:39:58,526 - Yep. - But all in all, it survived. 1135 00:39:58,657 --> 00:39:59,571 Good job. Well done. 1136 00:39:59,701 --> 00:40:01,007 - Thank you. 1137 00:40:01,137 --> 00:40:02,748 - Britt, Forest, 1138 00:40:02,878 --> 00:40:05,968 this has been an extremely tough competition. 1139 00:40:06,099 --> 00:40:07,579 For the first time ever, 1140 00:40:07,709 --> 00:40:10,059 we asked smiths to go back to their home forges 1141 00:40:10,190 --> 00:40:12,410 and make something other than a weapon. 1142 00:40:12,540 --> 00:40:14,760 And you've both proven that your Halligan tools 1143 00:40:14,890 --> 00:40:16,892 are "Forged in Fire" tough. 1144 00:40:17,023 --> 00:40:19,242 However, only one of you 1145 00:40:19,373 --> 00:40:21,593 can be the "Forged in Fire" champion. 1146 00:40:21,723 --> 00:40:25,205 And that champion is... 1147 00:40:25,335 --> 00:40:26,249 Britt. 1148 00:40:26,380 --> 00:40:27,512 Congratulations. 1149 00:40:27,642 --> 00:40:28,774 You're the "Forged in Fire" champion. 1150 00:40:28,904 --> 00:40:31,080 Forest, unfortunately, 1151 00:40:31,211 --> 00:40:33,648 your Halligan tool didn't make the cut. 1152 00:40:33,779 --> 00:40:35,084 - Well, Forest, you brought us 1153 00:40:35,215 --> 00:40:38,131 an attractive and functional rescue tool. 1154 00:40:38,261 --> 00:40:40,263 However, its lack of a defined corner 1155 00:40:40,394 --> 00:40:41,874 with flat striking surfaces 1156 00:40:42,004 --> 00:40:43,789 caused it to be a little less effective 1157 00:40:43,919 --> 00:40:45,181 than your competitor's. 1158 00:40:45,312 --> 00:40:47,357 And that's why we're letting you go. 1159 00:40:47,488 --> 00:40:48,968 - It's all right. 1160 00:40:49,098 --> 00:40:51,623 - Forest, you made a beautiful Damascus Halligan tool, 1161 00:40:51,753 --> 00:40:52,885 but at this time, 1162 00:40:53,015 --> 00:40:55,714 you're dismissed from the training area. 1163 00:40:55,844 --> 00:40:57,411 Good job, brother. Good job. - Thank you. 1164 00:40:57,542 --> 00:40:59,935 Britt and mine both performed well. 1165 00:41:00,066 --> 00:41:03,156 It just came down to some very minor design decisions, 1166 00:41:03,286 --> 00:41:06,028 and Britt made some better decisions than I did. 1167 00:41:06,159 --> 00:41:07,943 I'm exceptionally proud of the fact 1168 00:41:08,074 --> 00:41:09,989 of being able to represent the fire department. 1169 00:41:10,119 --> 00:41:12,687 Sorry I didn't come out on top, guys, but you know what? 1170 00:41:12,818 --> 00:41:14,080 We gave her a hell of a good go. 1171 00:41:14,210 --> 00:41:18,040 ♪ 1172 00:41:18,171 --> 00:41:19,955 - Britt, congratulations. 1173 00:41:20,086 --> 00:41:21,304 You are the "Forged in Fire" champion, 1174 00:41:21,435 --> 00:41:22,697 and that's a title that comes with a check for 1175 00:41:22,828 --> 00:41:23,872 $10,000. 1176 00:41:24,003 --> 00:41:24,917 Good job, man. [applause] 1177 00:41:25,047 --> 00:41:26,135 - Thank you, sir. Thank you. 1178 00:41:26,266 --> 00:41:27,485 I'm the "Forged in Fire" champion, 1179 00:41:27,615 --> 00:41:29,312 and it feels amazing. 1180 00:41:29,443 --> 00:41:31,445 I came in here confident that I had a pretty good shot. 1181 00:41:31,576 --> 00:41:33,403 Forest comes from the fire service side. 1182 00:41:33,534 --> 00:41:35,275 I come from the law enforcement side. 1183 00:41:35,405 --> 00:41:36,972 I thought he made a beautiful tool. 1184 00:41:37,103 --> 00:41:40,280 I simply just made a slightly better tool than he did, 1185 00:41:40,410 --> 00:41:41,760 and--and brought the win. 1186 00:41:41,890 --> 00:41:46,765 ♪