1 00:00:05,006 --> 00:00:07,631 [dramatic music] 2 00:00:07,717 --> 00:00:10,759 ♪ ♪ 3 00:00:10,845 --> 00:00:13,804 [tense music] 4 00:00:13,889 --> 00:00:15,222 ♪ ♪ 5 00:00:15,307 --> 00:00:16,890 - my name is chris coe, I'm 40 years old, 6 00:00:16,976 --> 00:00:19,143 and I've been bladesmithing for several years now. 7 00:00:19,228 --> 00:00:20,644 I have a huge appreciation 8 00:00:20,730 --> 00:00:22,396 for the military and the veterans. 9 00:00:22,481 --> 00:00:24,023 My father is a vietnam vet. 10 00:00:24,108 --> 00:00:25,858 He served in the united states army. 11 00:00:25,943 --> 00:00:28,819 He was in the infantry and on huey helicopters. 12 00:00:28,904 --> 00:00:30,529 This is a knife I made for my father 13 00:00:30,573 --> 00:00:33,073 out of recycled huey helicopter parts. 14 00:00:33,159 --> 00:00:35,409 I actually had to smuggle it out of his office 15 00:00:35,494 --> 00:00:37,870 to bring it here. 16 00:00:37,913 --> 00:00:40,789 - My name's brandon rader I'm 35 years old. 17 00:00:40,875 --> 00:00:42,166 I'm a disabled veteran. 18 00:00:42,251 --> 00:00:45,085 I was in the 173rd, 1st of 508. 19 00:00:45,171 --> 00:00:47,379 When I started bladesmithing, I realized there was 20 00:00:47,423 --> 00:00:49,381 more therapeutic things behind it, 21 00:00:49,425 --> 00:00:51,008 and it just kept going from there. 22 00:00:51,093 --> 00:00:52,509 I'm excited. No, it's gonna be 23 00:00:52,595 --> 00:00:55,179 a fun ride to party town. 24 00:00:55,264 --> 00:00:57,431 - My name's trish arno, and I'm 41 years old. 25 00:00:57,516 --> 00:00:59,683 I joined the army after 9/11 26 00:00:59,769 --> 00:01:01,602 because so many families lost their loved ones, 27 00:01:01,687 --> 00:01:03,145 and I wanted to be able to do something 28 00:01:03,230 --> 00:01:04,646 to give back to those families. 29 00:01:04,732 --> 00:01:06,190 During basic training, I sustained 30 00:01:06,275 --> 00:01:08,400 multiple stress fractures throughout both legs. 31 00:01:08,486 --> 00:01:11,070 They sent me home on an honorable medical discharge. 32 00:01:11,155 --> 00:01:14,073 I took up forging so I could kind of keep my body loose. 33 00:01:14,158 --> 00:01:16,158 It gave me a new purpose and brought 34 00:01:16,243 --> 00:01:17,951 a lot of life to me. 35 00:01:18,037 --> 00:01:20,245 - My name is mike rizzo. 36 00:01:20,331 --> 00:01:23,874 I'm 31 years old, and I'm a commercial building manager. 37 00:01:23,959 --> 00:01:25,667 I served in the army for four years 38 00:01:25,753 --> 00:01:27,127 and did a tour in iraq. 39 00:01:27,213 --> 00:01:30,214 The name of my forge is muffin man metalworks. 40 00:01:30,299 --> 00:01:32,091 The nickname came when I painted 41 00:01:32,134 --> 00:01:34,259 the room in my house "warm muffin." 42 00:01:34,303 --> 00:01:35,969 so now I'm known as the muffin man. 43 00:01:36,055 --> 00:01:37,679 [laughs] 44 00:01:37,765 --> 00:01:38,889 [suspenseful music] 45 00:01:38,974 --> 00:01:41,725 - bladesmiths, welcome to the forge. 46 00:01:41,811 --> 00:01:43,727 You're about to take part in three rounds 47 00:01:43,813 --> 00:01:45,729 of intense forging competition. 48 00:01:45,815 --> 00:01:47,397 At the end of each round, I want you to present your work 49 00:01:47,441 --> 00:01:49,066 to my panel of expert judges. 50 00:01:49,110 --> 00:01:50,317 The judges today are gonna be 51 00:01:50,361 --> 00:01:52,528 two-time "forged in fire" champion ben abbott. 52 00:01:52,613 --> 00:01:55,614 Next, we've got historic weapons re-creation specialist 53 00:01:55,699 --> 00:01:57,074 dave baker. 54 00:01:57,159 --> 00:01:59,409 And finally, edged weapon specialist 55 00:01:59,495 --> 00:02:01,870 and kali martial artist doug marcaida. 56 00:02:01,956 --> 00:02:04,331 Remember, there's $10,000 57 00:02:04,416 --> 00:02:05,791 and the title of "forged in fire" champion 58 00:02:05,876 --> 00:02:09,211 on the line, so I wanna see your absolute best work. 59 00:02:09,296 --> 00:02:12,131 Today in the forge, we're feeling a little patriotic. 60 00:02:12,174 --> 00:02:13,674 So we're gonna salute our veterans 61 00:02:13,759 --> 00:02:15,425 by giving you a competition unlike anything 62 00:02:15,511 --> 00:02:16,969 we've seen before. 63 00:02:17,054 --> 00:02:19,179 Today, we're not gonna ask you to build one blade. 64 00:02:19,265 --> 00:02:22,641 We're gonna ask you to build four different knives. 65 00:02:22,726 --> 00:02:24,434 Next to me, you see four crates. 66 00:02:24,478 --> 00:02:25,978 In each crate, there's a knife 67 00:02:26,021 --> 00:02:28,105 from the case american heroes knife series. 68 00:02:28,190 --> 00:02:30,691 Each one is codesigned by a distinguished veteran 69 00:02:30,776 --> 00:02:31,942 from the u.S. Military. 70 00:02:31,986 --> 00:02:33,443 Your challenge today is to come up, 71 00:02:33,529 --> 00:02:35,946 select a crate at random, and build the knife inside. 72 00:02:36,031 --> 00:02:38,282 But inside each crate, you'll also find 73 00:02:38,367 --> 00:02:39,783 a specific technique we want you to use 74 00:02:39,869 --> 00:02:41,618 to build that knife. 75 00:02:41,704 --> 00:02:44,079 Chris, come on up, select your blade. 76 00:02:44,165 --> 00:02:47,124 [dramatic music] 77 00:02:47,209 --> 00:02:53,338 ♪ ♪ 78 00:02:53,424 --> 00:02:55,632 you've selected the lamb hunter, 79 00:02:55,718 --> 00:02:57,801 codesigned by u.S. Army special missions unit 80 00:02:57,887 --> 00:02:59,678 sergeant major kyle lamb. 81 00:02:59,722 --> 00:03:01,096 This knife features deep finger grooves 82 00:03:01,182 --> 00:03:02,472 in the ricasso 83 00:03:02,558 --> 00:03:04,308 and a very effective spear-point tip. 84 00:03:04,393 --> 00:03:05,893 The design of this knife is well-suited 85 00:03:05,978 --> 00:03:06,977 for someone like kyle lamb, 86 00:03:07,062 --> 00:03:08,562 who's a professional outdoorsman. 87 00:03:08,647 --> 00:03:09,938 You see there you need to build your knife 88 00:03:10,024 --> 00:03:11,648 using a san mai method. 89 00:03:11,734 --> 00:03:13,400 - [bleep]. [laughs] 90 00:03:13,485 --> 00:03:16,486 san mai to me has always been the dark art. 91 00:03:16,530 --> 00:03:17,988 It's not my strong suit. 92 00:03:18,073 --> 00:03:19,323 - All right, brandon, you're up next. 93 00:03:19,408 --> 00:03:21,325 Come on up and select a crate. - Outstanding. 94 00:03:21,410 --> 00:03:28,040 ♪ ♪ 95 00:03:31,545 --> 00:03:33,670 - you selected the hambone. This knife was codesigned 96 00:03:33,756 --> 00:03:35,214 by medal of honor recipient 97 00:03:35,299 --> 00:03:37,507 u.S. Army staff sergeant clint romesha. 98 00:03:37,593 --> 00:03:39,218 This knife features an exposed tang at the pommel, 99 00:03:39,261 --> 00:03:41,803 wide bevels, and an upswept cutting edge. 100 00:03:41,889 --> 00:03:44,681 This knife was born from clint's love for the hunt, 101 00:03:44,767 --> 00:03:46,808 and it was made specifically for skinning game. 102 00:03:46,894 --> 00:03:48,310 You'll also notice on the spine of this weapon, 103 00:03:48,395 --> 00:03:49,686 there are eight stars. 104 00:03:49,772 --> 00:03:51,063 Each one was placed there to memorialize 105 00:03:51,106 --> 00:03:52,314 the team members clint lost 106 00:03:52,399 --> 00:03:53,982 during operation enduring freedom. 107 00:03:54,068 --> 00:03:55,525 And you'll see there you also have to build this knife 108 00:03:55,611 --> 00:03:57,819 using a twisted damascus pattern. 109 00:03:57,905 --> 00:04:00,948 All right, trish, come on up and select your crate. 110 00:04:01,033 --> 00:04:06,703 ♪ ♪ 111 00:04:06,789 --> 00:04:08,538 all right, you've chosen the skinner. 112 00:04:08,624 --> 00:04:10,582 This knife was codesigned by u.S. Army 113 00:04:10,668 --> 00:04:13,043 and u.S. Navy special operator kevin holland. 114 00:04:13,128 --> 00:04:15,254 This lightweight knife design features a flat grind 115 00:04:15,339 --> 00:04:16,546 and a distal taper. 116 00:04:16,632 --> 00:04:18,006 This here is a versatile knife. 117 00:04:18,092 --> 00:04:19,633 It was built for any camping situation 118 00:04:19,718 --> 00:04:21,385 or even as a reliable hunting knife. 119 00:04:21,428 --> 00:04:22,844 And just to make it a little harder, 120 00:04:22,930 --> 00:04:24,930 you're gonna need to use a canister damascus technique 121 00:04:25,015 --> 00:04:26,723 to build this knife. - Oh, yeah. 122 00:04:26,809 --> 00:04:29,643 Oh, god, kill me now. [laughs] 123 00:04:29,728 --> 00:04:31,270 skinner knife--no problem. 124 00:04:31,355 --> 00:04:32,604 Can is the problem. 125 00:04:32,690 --> 00:04:34,940 Gotta get past that before I can make a skinner. 126 00:04:35,025 --> 00:04:36,775 - Last but not least, mike. Come on up, man, 127 00:04:36,860 --> 00:04:38,402 select your crate. 128 00:04:38,487 --> 00:04:40,654 - What a selection. - Yeah. 129 00:04:40,739 --> 00:04:46,994 ♪ ♪ 130 00:04:47,079 --> 00:04:49,538 you've selected the recurve utility no. 6, 131 00:04:49,623 --> 00:04:51,164 codesigned by u.S. Navy 132 00:04:51,250 --> 00:04:52,833 special operator harry bologna. 133 00:04:52,918 --> 00:04:54,626 This knife features a thick spine for striking, 134 00:04:54,712 --> 00:04:57,337 an exposed tang at the pommel, and an s curve cutting edge 135 00:04:57,423 --> 00:04:59,381 made to maximize cutting ability. 136 00:04:59,466 --> 00:05:00,382 You've gotta build that knife 137 00:05:00,467 --> 00:05:02,634 using a raindrop pattern damascus. 138 00:05:02,720 --> 00:05:04,553 - [clicks tongue] - make sure you follow 139 00:05:04,638 --> 00:05:05,595 these parameters. 140 00:05:05,639 --> 00:05:06,680 Your knife needs to be between 141 00:05:06,765 --> 00:05:08,307 7 and 9 inches 142 00:05:08,392 --> 00:05:10,017 from tip to plunge grind, and in round two 143 00:05:10,102 --> 00:05:11,810 of this competition, you're gonna be adding handles 144 00:05:11,854 --> 00:05:14,104 to your knives, making them fully functioning weapons. 145 00:05:14,189 --> 00:05:15,689 We're gonna be checking your strength and durability 146 00:05:15,774 --> 00:05:18,442 doing an e-tool and canteen chop. 147 00:05:18,527 --> 00:05:19,609 And to test your edge retention, 148 00:05:19,695 --> 00:05:21,987 we'll be doing a gunpowder bag swipe. 149 00:05:22,072 --> 00:05:23,864 You'll only have three hours to complete these tasks, 150 00:05:23,949 --> 00:05:25,574 so good luck; do your best. 151 00:05:25,659 --> 00:05:27,284 Your time starts now. 152 00:05:27,369 --> 00:05:28,785 [exciting music] 153 00:05:28,871 --> 00:05:32,456 - ha-ha! - And the adventure continues! 154 00:05:32,541 --> 00:05:35,167 We've got veterans out there on the floor. 155 00:05:35,252 --> 00:05:37,294 Doug's a veteran, and you're a veteran too 156 00:05:37,379 --> 00:05:39,171 from the army, correct? - Yes, sir. 157 00:05:39,214 --> 00:05:41,256 I spent some time in the special forces 158 00:05:41,342 --> 00:05:42,466 during iraq. 159 00:05:42,551 --> 00:05:43,467 But it's good to see we've got 160 00:05:43,552 --> 00:05:44,760 some people in the forge today 161 00:05:44,845 --> 00:05:45,802 that support our brave warriors 162 00:05:45,888 --> 00:05:48,597 and come here to do their best. 163 00:05:48,682 --> 00:05:52,225 - 90% of metalwork is preparatory, 164 00:05:52,311 --> 00:05:55,854 so I'm cleaning every side on the grinder. 165 00:05:55,939 --> 00:05:59,316 - That prep at the beginning will save you so much time 166 00:05:59,401 --> 00:06:01,443 once those welds start to form. 167 00:06:01,528 --> 00:06:03,862 - That's kind of funny; my father, back in vietnam, 168 00:06:03,947 --> 00:06:05,155 he had a sergeant major who always talked about 169 00:06:05,240 --> 00:06:07,657 the seven ps: Proper prior planning 170 00:06:07,743 --> 00:06:10,285 prevents piss-poor performance. 171 00:06:10,371 --> 00:06:12,788 - I'm gonna use every single piece of steel 172 00:06:12,873 --> 00:06:15,540 given in front of me. 173 00:06:15,626 --> 00:06:17,167 - Holy cow. - [laughs] 174 00:06:17,252 --> 00:06:19,628 - you guys seeing the size of mike's stack over here? 175 00:06:19,713 --> 00:06:22,589 - I'm starting off with more layers than I need, 176 00:06:22,674 --> 00:06:24,549 but I'd rather have it and not need it 177 00:06:24,635 --> 00:06:26,635 than need it and not have it. That's a saying, right? 178 00:06:26,720 --> 00:06:27,803 [laughs] 179 00:06:27,888 --> 00:06:29,346 [rock music] 180 00:06:29,431 --> 00:06:30,931 - I'm excited about this knife. 181 00:06:31,016 --> 00:06:33,433 It looks like a camp knife designed by rambo. 182 00:06:33,519 --> 00:06:35,227 - That canister is large. 183 00:06:35,270 --> 00:06:37,396 That's gonna be a lot of steel to work with. 184 00:06:37,439 --> 00:06:38,814 You can cut a lot of that material off 185 00:06:38,899 --> 00:06:40,607 and save it as backup. 186 00:06:40,692 --> 00:06:42,734 - I know I'm gonna have to peel it off 187 00:06:42,820 --> 00:06:44,778 instead of shaving it off so that I can make sure 188 00:06:44,863 --> 00:06:45,946 I have a hardenable edge. 189 00:06:46,031 --> 00:06:47,864 - So it looks like trish put white out 190 00:06:47,950 --> 00:06:50,117 in her canister, but she's letting it sit. 191 00:06:50,202 --> 00:06:51,660 - Yeah, very important. 192 00:06:51,745 --> 00:06:53,703 We see a lot of the smiths rush the process, 193 00:06:53,789 --> 00:06:55,914 and they wind up putting white out on everything 194 00:06:55,999 --> 00:06:57,999 they put in the can. 195 00:06:58,085 --> 00:07:01,711 - Do not stab me. Ouch. 196 00:07:01,797 --> 00:07:05,882 - San mai's the process of having a hardened billet 197 00:07:05,968 --> 00:07:09,428 with a soft outer jacket on the blade, 198 00:07:09,513 --> 00:07:12,264 and I don't have a lot of experience with it. 199 00:07:12,307 --> 00:07:14,891 So it's gonna be uphill battle from the get-go. 200 00:07:14,977 --> 00:07:17,269 - Ben, there's two ways to make san mai, right? 201 00:07:17,354 --> 00:07:19,646 - Yeah, the taco method, where you take 202 00:07:19,731 --> 00:07:21,398 a piece of mild steel and you wrap it 203 00:07:21,483 --> 00:07:22,899 around the high carbon steel. 204 00:07:22,985 --> 00:07:24,234 Another way is, you just start 205 00:07:24,319 --> 00:07:25,569 with three separate pieces of steel. 206 00:07:25,654 --> 00:07:27,654 That way, you see on the spine 207 00:07:27,739 --> 00:07:30,031 and on the blade that inner core. 208 00:07:30,117 --> 00:07:31,783 - I'm drawing out the mild steel first 209 00:07:31,869 --> 00:07:34,536 because I'm thinking it would be the quickest thing 210 00:07:34,621 --> 00:07:36,371 to work with. 211 00:07:36,457 --> 00:07:37,539 [groans] 212 00:07:37,624 --> 00:07:38,915 [dramatic music] 213 00:07:39,001 --> 00:07:41,293 the mild steel did not go as planned. 214 00:07:41,378 --> 00:07:43,003 I know I'm gonna have to start over 215 00:07:43,088 --> 00:07:45,046 while there's still time on the clock. 216 00:07:45,132 --> 00:07:46,423 Yeah, I got a big problem with that. 217 00:07:46,467 --> 00:07:47,924 We ain't coming back from it. 218 00:07:48,010 --> 00:07:50,969 One of those days. [laughs] 219 00:07:51,054 --> 00:07:54,306 - almost ready to start moving metal. 220 00:07:54,349 --> 00:07:56,433 Before I start making this knife, 221 00:07:56,477 --> 00:07:57,934 I gotta get my steel together. 222 00:07:58,020 --> 00:07:59,728 I need to start alternating layers 223 00:07:59,813 --> 00:08:01,396 so that way the pattern will show up 224 00:08:01,482 --> 00:08:03,440 with the different kinds of metal. 225 00:08:03,525 --> 00:08:06,318 - Brandon is worrying me. That billet is not hot enough. 226 00:08:06,403 --> 00:08:08,904 - Oh! Did you see that? 227 00:08:08,989 --> 00:08:11,531 - Yeah. - Come on with it. 228 00:08:11,617 --> 00:08:14,034 No plan survives first contact. 229 00:08:14,119 --> 00:08:16,453 I knew I had to break off, regroup, 230 00:08:16,538 --> 00:08:17,954 adapt, improvise, overcome, 231 00:08:17,998 --> 00:08:19,831 and move on to the next objective. 232 00:08:19,917 --> 00:08:22,751 - Brandon lost some of his metal, 233 00:08:22,836 --> 00:08:26,171 and it is a very skinny billet that he has right now. 234 00:08:26,215 --> 00:08:28,632 - He probably should have started over. 235 00:08:28,717 --> 00:08:30,592 - There's still one fully forged, welded 236 00:08:30,677 --> 00:08:31,885 on the end of the stick. 237 00:08:31,929 --> 00:08:34,596 I'm not gonna have as much steel as I wanted, 238 00:08:34,681 --> 00:08:37,599 but I'll work with it. 239 00:08:37,684 --> 00:08:40,310 - Two hours remaining! 240 00:08:40,395 --> 00:08:42,562 - My welds appear to be solid, 241 00:08:42,648 --> 00:08:45,398 and I'm going to make another two passes 242 00:08:45,484 --> 00:08:47,400 just to make sure they're super solid. 243 00:08:47,486 --> 00:08:50,237 - The guy in the lead right now is mike. 244 00:08:50,322 --> 00:08:51,988 Now it's just a matter of putting 245 00:08:52,032 --> 00:08:53,698 the raindrop pattern in there. 246 00:08:53,742 --> 00:08:55,951 - To get a good pattern, you need a lot of layers. 247 00:08:56,036 --> 00:08:57,953 - Even after 19 layers, 248 00:08:58,038 --> 00:09:02,791 I now have 19 different points where something could fail. 249 00:09:02,876 --> 00:09:06,670 So I'd rather not risk cutting and restacking it 250 00:09:06,755 --> 00:09:08,922 and starting that whole process all over again. 251 00:09:09,007 --> 00:09:11,258 It's all about making it look good, right? 252 00:09:11,343 --> 00:09:13,343 [laughs] - now I know how david felt 253 00:09:13,428 --> 00:09:15,804 against goliath. - [laughs] 254 00:09:15,889 --> 00:09:17,514 [rock music] 255 00:09:17,599 --> 00:09:19,391 - looks like trish is in the press right now, 256 00:09:19,434 --> 00:09:21,268 using the squaring dies. - Yeah, and I don't think 257 00:09:21,353 --> 00:09:23,019 that billet was hot enough either. 258 00:09:23,105 --> 00:09:24,229 ♪ ♪ 259 00:09:24,314 --> 00:09:27,107 - ah, [bleep]! - Oh, no. 260 00:09:27,192 --> 00:09:29,234 - I'm seeing these sparks, and I know 261 00:09:29,319 --> 00:09:31,152 that that means that the powdered steel 262 00:09:31,238 --> 00:09:33,029 is still in powdered form. 263 00:09:33,115 --> 00:09:35,282 It's not compressed, so now I'm letting 264 00:09:35,367 --> 00:09:38,785 oxygen into the canister and just creating 265 00:09:38,870 --> 00:09:41,121 all kinds of inclusions and delaminations 266 00:09:41,206 --> 00:09:42,372 throughout that billet. 267 00:09:42,416 --> 00:09:44,708 I don't know if that's salvageable. 268 00:09:44,793 --> 00:09:47,252 Think I'm gonna need a new can. 269 00:09:47,296 --> 00:09:49,170 - Even though that billet was leaking, 270 00:09:49,256 --> 00:09:50,463 it didn't leak that badly. 271 00:09:50,549 --> 00:09:52,924 She could have gone over, welded that hole closed, 272 00:09:52,968 --> 00:09:54,301 and continued to work on it. 273 00:09:54,386 --> 00:09:56,344 She didn't need to build a new one. 274 00:09:56,430 --> 00:09:59,347 - Hail mary time. 275 00:09:59,433 --> 00:10:00,807 [heavy metal music] 276 00:10:00,892 --> 00:10:03,560 - I have a good set of forge-welded damascus. 277 00:10:03,645 --> 00:10:05,520 Now it's time to set the pattern. 278 00:10:05,606 --> 00:10:07,606 I fired, so hopefully I got enough 279 00:10:07,691 --> 00:10:09,691 to twist it and then draw it back out. 280 00:10:09,776 --> 00:10:12,027 - When you do that twist, you lose a lot of material, 281 00:10:12,112 --> 00:10:14,529 and if you're just close to what you need with the twist, 282 00:10:14,615 --> 00:10:17,449 you're not gonna have enough by the time you grind it. 283 00:10:17,534 --> 00:10:19,326 - I'm gonna try to twist this steel 284 00:10:19,411 --> 00:10:21,703 as much as I can without getting any kind 285 00:10:21,788 --> 00:10:24,205 of delaminations on it and still have enough twist 286 00:10:24,291 --> 00:10:26,541 in there to pull a pretty pattern. 287 00:10:26,627 --> 00:10:29,252 The whole machine just starts pushing and rocking on me. 288 00:10:29,338 --> 00:10:31,171 I gotta bury my knee into it. 289 00:10:31,256 --> 00:10:33,465 It doesn't have as many twists as I want, 290 00:10:33,550 --> 00:10:35,925 but I think I have enough steel at this point 291 00:10:36,011 --> 00:10:37,427 to get the dimensions and widths 292 00:10:37,512 --> 00:10:39,095 and still pull the pattern out. 293 00:10:39,181 --> 00:10:42,557 We're getting there, brother. We're getting there, now. 294 00:10:42,643 --> 00:10:44,726 [exciting music] 295 00:10:44,811 --> 00:10:46,728 - after the attempt with the mild steel failed, 296 00:10:46,813 --> 00:10:48,688 I realized that I should have just started 297 00:10:48,774 --> 00:10:51,524 with the high carbon billet and worked from there. 298 00:10:51,610 --> 00:10:53,276 - Chris is still just drawing out 299 00:10:53,362 --> 00:10:54,778 the three components of his san mai. 300 00:10:54,863 --> 00:10:57,113 I don't think he's ever forged welded them together yet. 301 00:10:57,199 --> 00:11:01,826 - The clock is not my friend. I have to get moving. 302 00:11:01,912 --> 00:11:04,287 - Come on, little can. 303 00:11:04,373 --> 00:11:06,206 After the first can was so big, 304 00:11:06,291 --> 00:11:07,999 I'm thinking maybe two smaller ones 305 00:11:08,085 --> 00:11:09,876 will fare better for me. 306 00:11:09,961 --> 00:11:11,711 - Do you think there's any coming back from this? 307 00:11:11,797 --> 00:11:14,130 - Well, there's the legend of neil kamimura. 308 00:11:14,216 --> 00:11:17,133 He did a knife from a raw can 309 00:11:17,219 --> 00:11:19,678 to something on the table in 32 minutes. 310 00:11:19,721 --> 00:11:22,138 - She's got quite a bit more than that at this point. 311 00:11:22,224 --> 00:11:23,932 - [groans] 312 00:11:24,017 --> 00:11:26,142 I am screwed! 313 00:11:26,228 --> 00:11:28,770 - That billet is not hot enough. 314 00:11:28,855 --> 00:11:30,146 [dramatic music] 315 00:11:30,232 --> 00:11:31,648 - the heat in here is no joke. 316 00:11:31,733 --> 00:11:34,651 I did basic training in south carolina, 317 00:11:34,736 --> 00:11:37,153 in the dead of summer, but this is like 318 00:11:37,239 --> 00:11:41,199 standing in the desert next to a lava flow. 319 00:11:41,284 --> 00:11:43,076 - One hour remaining! 320 00:11:43,161 --> 00:11:44,828 ♪ ♪ 321 00:11:44,913 --> 00:11:46,204 - you okay? 322 00:11:46,248 --> 00:11:47,831 - I'm hot and dizzy. 323 00:11:47,916 --> 00:11:49,416 - You're dizzy? 324 00:11:49,501 --> 00:11:51,543 - I can't breathe. I can't catch my breath. 325 00:11:51,586 --> 00:11:53,837 I know I have to get out of here. 326 00:11:53,922 --> 00:11:55,839 - It looks like trish just got escorted 327 00:11:55,924 --> 00:11:57,006 off the floor by the medic. 328 00:11:57,092 --> 00:11:59,259 - Yeah, I think she's reached her limit. 329 00:11:59,344 --> 00:12:04,055 ♪ ♪ 330 00:12:04,099 --> 00:12:05,432 off the floor by the medic. 331 00:12:05,517 --> 00:12:07,892 - The physical aspect of these competitions 332 00:12:07,978 --> 00:12:09,602 can be brutal. 333 00:12:09,688 --> 00:12:11,688 - In my head, I wanna go, 334 00:12:11,773 --> 00:12:14,274 but body's just like, "you're done." 335 00:12:14,359 --> 00:12:16,109 - so what do you wanna do? 336 00:12:16,194 --> 00:12:17,277 'cause it's ultimately up to you. 337 00:12:17,362 --> 00:12:18,653 - I wanna give it one last hoorah. 338 00:12:18,739 --> 00:12:19,612 - Okay. - I didn't come here 339 00:12:19,698 --> 00:12:21,197 to friggin' quit. 340 00:12:21,241 --> 00:12:23,199 I'm not gonna stop. I'm gonna keep going. 341 00:12:23,285 --> 00:12:25,326 - Hey, look who's back! 342 00:12:25,412 --> 00:12:26,494 - Welcome back! - Welcome! 343 00:12:26,580 --> 00:12:28,621 - Great. - I ain't dead yet! 344 00:12:28,707 --> 00:12:30,081 - Let's go! 345 00:12:30,167 --> 00:12:32,083 - It doesn't matter how much time's on that clock. 346 00:12:32,169 --> 00:12:34,753 I am going to take what's left of the first billet, 347 00:12:34,838 --> 00:12:36,880 and I'm gonna just try to put out there 348 00:12:36,965 --> 00:12:38,423 whatever I can. 349 00:12:38,467 --> 00:12:40,049 - If she's got 2/3 of that billet 350 00:12:40,135 --> 00:12:42,135 welded together, she's got more than enough metal 351 00:12:42,220 --> 00:12:45,096 to make that knife. 352 00:12:45,182 --> 00:12:46,347 [rock music] 353 00:12:46,433 --> 00:12:48,057 - now it's time to do my raindrop pattern. 354 00:12:48,143 --> 00:12:49,976 - To do raindrops, you just drill 355 00:12:50,061 --> 00:12:52,812 some shallow impressions in your billet 356 00:12:52,898 --> 00:12:54,814 and then forge it out. You've got a raindrop pattern. 357 00:12:54,900 --> 00:12:57,400 - [laughs] the drill bit's glowing. 358 00:12:57,444 --> 00:12:59,319 - Right? 359 00:12:59,404 --> 00:13:03,072 - It's a struggle to just get any sort of drill bit 360 00:13:03,158 --> 00:13:04,783 to drill into the billet. 361 00:13:04,868 --> 00:13:06,659 - Hey, mike, how many bits is that so far? 362 00:13:06,745 --> 00:13:09,370 - [laughs] it's chewing right through 'em. 363 00:13:09,456 --> 00:13:11,164 - Mike is drilling on very hot steel 364 00:13:11,249 --> 00:13:13,625 and ruining the temper of his drill bit. 365 00:13:13,710 --> 00:13:15,627 - I'm really not a fan of raindrop damascus 366 00:13:15,712 --> 00:13:17,086 at this point. 367 00:13:17,172 --> 00:13:20,465 I'm no weatherman, but I think that's some raindrops. 368 00:13:20,509 --> 00:13:21,841 - Whoa! 369 00:13:21,927 --> 00:13:24,302 - Okay, now, finally, 370 00:13:24,346 --> 00:13:26,012 with less than an hour remaining, 371 00:13:26,097 --> 00:13:28,139 chris is tack welding his three layers 372 00:13:28,183 --> 00:13:29,808 for his san mai billet. 373 00:13:29,893 --> 00:13:32,852 - I have to get this thing forge welded. 374 00:13:32,938 --> 00:13:34,979 Not going very good. 375 00:13:35,065 --> 00:13:37,941 I have a really bad offset on the tip, 376 00:13:38,026 --> 00:13:39,651 where one side's thicker than the other. 377 00:13:39,694 --> 00:13:41,569 I should have welded up further to the tip 378 00:13:41,655 --> 00:13:43,488 and then blended that in that way, 379 00:13:43,573 --> 00:13:46,783 but I'm just trying to work with what I got. 380 00:13:46,868 --> 00:13:47,867 [dramatic music] 381 00:13:47,953 --> 00:13:49,369 - brandon quenched. 382 00:13:49,454 --> 00:13:51,287 ♪ ♪ 383 00:13:51,373 --> 00:13:52,956 - [groans] 384 00:13:53,041 --> 00:13:55,792 attention to details-- forgot the stars, brother. 385 00:13:55,877 --> 00:13:58,378 The stars on the spine of this blade represent 386 00:13:58,463 --> 00:14:00,338 the eight members of clint romesha's team 387 00:14:00,423 --> 00:14:01,631 that did not make it back. 388 00:14:01,716 --> 00:14:03,842 So I cannot forget to put these stars 389 00:14:03,927 --> 00:14:05,134 on the back of this knife. 390 00:14:05,220 --> 00:14:07,011 I have to put it back in the forge 391 00:14:07,097 --> 00:14:09,389 so I can work with the metal and chisel it in. 392 00:14:09,474 --> 00:14:11,307 - Instead of putting those stars in now, 393 00:14:11,393 --> 00:14:13,268 he doesn't need to do that until the next round. 394 00:14:13,353 --> 00:14:16,020 - Well, if he wants to do it on the soft steel, 395 00:14:16,106 --> 00:14:18,314 he has to do it before he quenches. 396 00:14:18,400 --> 00:14:19,524 - All right. 397 00:14:19,568 --> 00:14:20,984 I'm gonna have to re-quench it, 398 00:14:21,069 --> 00:14:23,194 and it's a risky choice because it's already been 399 00:14:23,280 --> 00:14:25,280 heat-treated and hardened. 400 00:14:25,365 --> 00:14:27,740 And I can get delamination, fractures-- 401 00:14:27,826 --> 00:14:30,410 all kinds of stuff can go wrong. 402 00:14:30,495 --> 00:14:32,829 Ooh! She hard, man. 403 00:14:32,914 --> 00:14:35,582 - 20 minutes remaining on the clock! 404 00:14:35,667 --> 00:14:37,000 - I'm running out of time. 405 00:14:37,043 --> 00:14:38,918 I gotta get something going here. 406 00:14:39,004 --> 00:14:41,379 - It seems like what trish is gonna do now 407 00:14:41,464 --> 00:14:44,173 is attempt to peel that can away. 408 00:14:44,259 --> 00:14:47,635 - There we go! Finally! 409 00:14:47,721 --> 00:14:49,888 I don't care what it is. I'm turning in something. 410 00:14:49,931 --> 00:14:51,639 I'd rather get a lump of coal for christmas 411 00:14:51,725 --> 00:14:53,516 than nothing at all. [laughs] 412 00:14:53,602 --> 00:14:56,311 - trish is working to the end. I like that. 413 00:14:56,396 --> 00:14:58,021 - It kind of gets my heart going a little bit. 414 00:14:58,106 --> 00:14:59,355 It brings you back to my time in training, 415 00:14:59,441 --> 00:15:02,275 when the first thing that came to my mind is "quit." 416 00:15:02,360 --> 00:15:03,902 it's the easiest thing to do. 417 00:15:03,987 --> 00:15:06,070 The hardest thing to do is to stick it out. 418 00:15:06,114 --> 00:15:07,739 ♪ ♪ 419 00:15:07,782 --> 00:15:09,782 five minutes remaining! 420 00:15:09,868 --> 00:15:12,619 - And three of our blades have not been quenched. 421 00:15:12,704 --> 00:15:14,871 - I'm getting ready to quench to blade. 422 00:15:14,956 --> 00:15:16,581 It could warp. I could delam. 423 00:15:16,666 --> 00:15:18,917 It could twist. It could crack. 424 00:15:19,002 --> 00:15:20,043 I don't have enough time on the clock 425 00:15:20,128 --> 00:15:21,878 for any of that. 426 00:15:21,922 --> 00:15:25,131 - And we got a quench. Chris quenched. 427 00:15:25,216 --> 00:15:26,925 - The clock is ticking away, 428 00:15:27,010 --> 00:15:28,551 and I gotta get this thing in the oil. 429 00:15:28,637 --> 00:15:31,095 - Just quench it. 430 00:15:31,139 --> 00:15:33,765 - There's a quench. - Thank you! 431 00:15:33,808 --> 00:15:35,808 - I'm just hoping I got a straight blade. 432 00:15:35,894 --> 00:15:38,645 - Trish could run with a hail mary quench right now. 433 00:15:38,730 --> 00:15:39,771 - She's not giving up. 434 00:15:39,856 --> 00:15:42,315 - No, she's not. She's tough. 435 00:15:42,400 --> 00:15:45,652 - Five, four, three, 436 00:15:45,737 --> 00:15:47,236 two, one! 437 00:15:47,280 --> 00:15:48,947 Bladesmiths, put down your weapons! 438 00:15:48,990 --> 00:15:50,281 Turn off your machines! 439 00:15:50,325 --> 00:15:52,241 This round of competition is over! 440 00:15:52,327 --> 00:15:53,576 [tense music] 441 00:15:53,662 --> 00:15:55,161 - time's up and I'm looking at 442 00:15:55,246 --> 00:15:57,330 the first incomplete knife I've ever made. 443 00:15:57,415 --> 00:15:59,374 So I know I'm as cooked as that piece of steel 444 00:15:59,459 --> 00:16:02,126 on that anvil, but I didn't go down without a fight. 445 00:16:02,170 --> 00:16:05,004 ♪ ♪ 446 00:16:05,090 --> 00:16:07,507 - bladesmiths, in round one, you had three hours 447 00:16:07,592 --> 00:16:09,717 to work on your case american hero knives. 448 00:16:09,803 --> 00:16:11,636 It was an absolute tough one, so thank you 449 00:16:11,721 --> 00:16:13,012 for giving your best work. 450 00:16:13,098 --> 00:16:14,514 Unfortunately, trish, in that time, 451 00:16:14,599 --> 00:16:16,432 you weren't able to finish your knife, 452 00:16:16,518 --> 00:16:18,518 but I wanna say thank you because although it was 453 00:16:18,603 --> 00:16:20,687 extremely difficult, you ran up against the wall 454 00:16:20,772 --> 00:16:22,689 countless times, you didn't give up. 455 00:16:22,774 --> 00:16:24,816 So I'm gonna ask you to surrender your steel 456 00:16:24,901 --> 00:16:26,901 and leave the forge floor. - Yes, sir. 457 00:16:26,987 --> 00:16:28,444 Thank you, guys. 458 00:16:28,488 --> 00:16:30,321 I'm proud of myself for sticking in there. 459 00:16:30,407 --> 00:16:32,156 You know, obviously, I wish I could have 460 00:16:32,242 --> 00:16:34,784 produced something more knife-looking. 461 00:16:34,869 --> 00:16:36,035 I'm sorry I couldn't give you something better. 462 00:16:36,121 --> 00:16:37,704 - [laughs] - you never quit, girl. 463 00:16:37,789 --> 00:16:39,163 That's--that's what it's about. 464 00:16:39,207 --> 00:16:40,665 - Good luck, guys. 465 00:16:40,750 --> 00:16:43,793 I didn't give up because I don't quit. 466 00:16:43,878 --> 00:16:45,420 I'm stubborn. [laughs] 467 00:16:45,505 --> 00:16:47,171 that's why I joined the army. 468 00:16:47,215 --> 00:16:49,674 ♪ ♪ 469 00:16:49,759 --> 00:16:50,842 - all right, gentlemen, you're still here. 470 00:16:50,885 --> 00:16:52,010 Congratulations. But we're not out 471 00:16:52,095 --> 00:16:53,678 of the woods yet. At this point, 472 00:16:53,722 --> 00:16:55,138 I'm gonna have the judges check your blades 473 00:16:55,223 --> 00:16:56,681 and make sure you're within parameters. 474 00:16:56,725 --> 00:16:59,058 Mike, you had the recurve utility no. 6, 475 00:16:59,144 --> 00:17:00,560 codesigned by harry bologna. 476 00:17:00,645 --> 00:17:02,979 Please present your weapon. 477 00:17:03,064 --> 00:17:04,439 [dramatic music] 478 00:17:04,524 --> 00:17:05,690 - hi, mike. 479 00:17:05,775 --> 00:17:07,692 You did a great job on this so far. 480 00:17:07,777 --> 00:17:10,194 Some of the little issues: The handle, in general, 481 00:17:10,280 --> 00:17:11,529 is really massive. 482 00:17:11,614 --> 00:17:13,364 It's got another inch and a half 483 00:17:13,408 --> 00:17:14,949 to what it needs to have. 484 00:17:15,035 --> 00:17:16,701 But all your welds are tight. 485 00:17:16,745 --> 00:17:19,203 Well done. - Thank you. 486 00:17:19,247 --> 00:17:22,206 - Brandon, you had the hambone, codesigned by clint romesha. 487 00:17:22,250 --> 00:17:23,750 Please present your work. 488 00:17:23,835 --> 00:17:25,668 ♪ ♪ 489 00:17:25,754 --> 00:17:26,919 - all right, brandon. 490 00:17:27,005 --> 00:17:28,713 When you lost half your stack, 491 00:17:28,798 --> 00:17:30,423 you got us worried over here 'cause it looked like 492 00:17:30,508 --> 00:17:32,633 a very lean billet that you had, 493 00:17:32,719 --> 00:17:34,343 but you made it through. 494 00:17:34,429 --> 00:17:36,596 I can see the twist pattern right there. 495 00:17:36,681 --> 00:17:38,181 Good job on that. 496 00:17:38,266 --> 00:17:39,932 And I really appreciate that you got 497 00:17:40,018 --> 00:17:42,101 the eight stars in there to really commemorate 498 00:17:42,187 --> 00:17:44,854 and give homage to what romesha was really trying to do 499 00:17:44,939 --> 00:17:46,272 with the hambone knife. 500 00:17:46,357 --> 00:17:48,107 Good job. 501 00:17:48,193 --> 00:17:49,400 - All right, chris, you're up next. 502 00:17:49,486 --> 00:17:51,861 You had the lamb hunter in the san mai method. 503 00:17:51,946 --> 00:17:53,780 Please present your work. 504 00:17:53,865 --> 00:17:55,573 ♪ ♪ 505 00:17:55,617 --> 00:17:58,618 - right off the bat, you do have a san mai happening here, 506 00:17:58,703 --> 00:18:00,953 but that hard core has a crack in it 507 00:18:01,039 --> 00:18:02,914 that goes right across the blade edge. 508 00:18:02,999 --> 00:18:04,499 That has to be dealt with. 509 00:18:04,584 --> 00:18:06,250 If we move into testing, we've almost got 510 00:18:06,336 --> 00:18:07,919 a blade that's guaranteed to fail. 511 00:18:07,962 --> 00:18:10,296 From now on, it's just refining 512 00:18:10,381 --> 00:18:13,966 what you've got going here and fixing this issue. 513 00:18:14,052 --> 00:18:15,802 - Guys, congratulations. 514 00:18:15,887 --> 00:18:17,303 You made it past round one. 515 00:18:17,388 --> 00:18:18,805 We're moving into round two. 516 00:18:18,890 --> 00:18:20,515 At this point, we're gonna ask you 517 00:18:20,600 --> 00:18:21,933 to put scales on your blades, 518 00:18:22,018 --> 00:18:23,643 making them fully-functioning weapons, 519 00:18:23,728 --> 00:18:26,395 using only the synthetic materials in the pantry. 520 00:18:26,481 --> 00:18:27,814 Any of the unique features you have 521 00:18:27,899 --> 00:18:29,690 in your case american heroes knives, 522 00:18:29,776 --> 00:18:31,400 we wanna see those at the end of this round. 523 00:18:31,486 --> 00:18:34,153 We'll be testing the durability and strength of your weapons 524 00:18:34,239 --> 00:18:36,614 in the e-tool and canteen chop, 525 00:18:36,658 --> 00:18:37,949 and checking your edge retention 526 00:18:37,992 --> 00:18:39,742 in the gunpowder bag slice. 527 00:18:39,828 --> 00:18:41,744 You only have two hours to complete your work. 528 00:18:41,788 --> 00:18:43,162 So good luck. 529 00:18:43,248 --> 00:18:45,665 Your time starts now. 530 00:18:45,750 --> 00:18:48,334 [upbeat rock music] 531 00:18:48,419 --> 00:18:50,211 ♪ ♪ 532 00:18:50,296 --> 00:18:51,712 based on what you guys said in the critique, 533 00:18:51,798 --> 00:18:54,674 it sounds like chris has absolutely the most to do 534 00:18:54,759 --> 00:18:55,716 in this round. 535 00:18:55,802 --> 00:18:57,301 - He's got a crack that runs 536 00:18:57,387 --> 00:18:58,803 right across the edge of the blade. 537 00:18:58,888 --> 00:19:01,055 He needs to fill that with weld 538 00:19:01,141 --> 00:19:04,308 and then do an edge quench, or chris is going to lose 539 00:19:04,394 --> 00:19:07,270 the temper on either side of that weld. 540 00:19:07,355 --> 00:19:09,105 - My blade might not be in the best shape, 541 00:19:09,190 --> 00:19:11,315 but I'm confident I can turn this around. 542 00:19:11,401 --> 00:19:13,568 - I think it's safe to say chris is gonna be 543 00:19:13,653 --> 00:19:15,278 re-quenching his blade. 544 00:19:15,321 --> 00:19:16,612 What do you think could go wrong? 545 00:19:16,698 --> 00:19:18,322 - It's gonna be too soft. 546 00:19:18,408 --> 00:19:19,866 It's not gonna hold up to the test, 547 00:19:19,951 --> 00:19:22,493 so we're gonna see some rolling. 548 00:19:22,537 --> 00:19:26,164 - A three-hour round one was a time crunch. 549 00:19:26,207 --> 00:19:29,125 Two hours is just a whole nother ball game, 550 00:19:29,210 --> 00:19:31,252 and I'm really feeling the stress. 551 00:19:31,337 --> 00:19:33,838 - Mike has a handle that's so wicked long, 552 00:19:33,923 --> 00:19:35,006 so it's out of proportion. 553 00:19:35,049 --> 00:19:36,299 [tense music] 554 00:19:36,342 --> 00:19:38,509 - now that I've got my tang shortened, 555 00:19:38,595 --> 00:19:41,554 I immediately start slotting some little channels 556 00:19:41,639 --> 00:19:44,223 above my tang for a thumb grip. 557 00:19:44,309 --> 00:19:47,810 Am I 100% happy with my blade shape? 558 00:19:47,896 --> 00:19:48,936 Of course not. 559 00:19:49,022 --> 00:19:50,688 Time is not on our side here, 560 00:19:50,773 --> 00:19:54,942 so I gotta move on to create this handle. 561 00:19:55,028 --> 00:19:56,861 - I'm feeling good. 562 00:19:56,946 --> 00:19:58,571 I got the holes drilled in my handle. 563 00:19:58,656 --> 00:20:00,740 Coming up behind you, brother. 564 00:20:00,825 --> 00:20:02,700 I move back over to my work station... 565 00:20:02,785 --> 00:20:04,243 [rock music] 566 00:20:04,329 --> 00:20:07,079 what in the world did I do? 567 00:20:07,165 --> 00:20:10,041 And that's when I realized I missed one of the holes, 568 00:20:10,084 --> 00:20:11,292 and it does not match up. 569 00:20:11,377 --> 00:20:13,753 You gotta be [bleep] with me, man. 570 00:20:13,838 --> 00:20:16,505 If I don't fix this issue, scale's gonna break off. 571 00:20:16,591 --> 00:20:18,507 It's gonna fail. 572 00:20:18,593 --> 00:20:20,426 - Is brandon cutting out new handle scales? 573 00:20:20,511 --> 00:20:23,054 - Sometimes the best thing to do 574 00:20:23,139 --> 00:20:26,974 is not try to fix the problem, but just start over. 575 00:20:27,060 --> 00:20:29,227 - It's time to choose my handle material, 576 00:20:29,312 --> 00:20:32,521 and I see this honeycomb pattern. 577 00:20:32,607 --> 00:20:34,106 That's the handle I want on it. 578 00:20:34,192 --> 00:20:37,068 It's indexable. They're all symmetric shapes. 579 00:20:37,111 --> 00:20:39,278 If I can align one side up 580 00:20:39,364 --> 00:20:41,239 and drill through to the other side, 581 00:20:41,282 --> 00:20:43,741 I have a mirror image of the other side. 582 00:20:43,785 --> 00:20:45,785 It basically aligned itself. 583 00:20:45,870 --> 00:20:46,994 - Looks like we got chris gluing up 584 00:20:47,080 --> 00:20:48,246 his handle scales now. 585 00:20:48,331 --> 00:20:50,456 - I'm shocked that I made up this much time 586 00:20:50,541 --> 00:20:51,916 making the handles. 587 00:20:52,001 --> 00:20:54,543 - Gentlemen, you got one hour remaining! 588 00:20:54,629 --> 00:20:57,880 - I have all the holes drilled on one scale. 589 00:20:57,966 --> 00:21:00,007 Now I'm trying to do a mock fit up 590 00:21:00,093 --> 00:21:02,385 of the other scale. 591 00:21:02,428 --> 00:21:03,761 [bleep]! 592 00:21:03,805 --> 00:21:07,431 And we're off by just fractions of an inch. 593 00:21:07,475 --> 00:21:10,893 Struggling to get this thing to line up together. 594 00:21:10,979 --> 00:21:13,771 The longer I spend messing around with these pins, 595 00:21:13,856 --> 00:21:16,899 the less time I have to finish my blade. 596 00:21:16,943 --> 00:21:22,905 [bleep]! 597 00:21:22,949 --> 00:21:26,158 To line up together to get a handle glued up. 598 00:21:26,244 --> 00:21:27,451 [dramatic music] 599 00:21:27,537 --> 00:21:29,578 [drill whirring] 600 00:21:29,664 --> 00:21:32,957 I'm just oblong-ing the holes to make it work. 601 00:21:33,001 --> 00:21:34,834 If one of those pins doesn't line up, 602 00:21:34,919 --> 00:21:38,212 I'm just gonna fill it with goop and hope it works. 603 00:21:38,298 --> 00:21:40,256 ♪ ♪ 604 00:21:40,300 --> 00:21:41,465 [rock music] 605 00:21:41,509 --> 00:21:42,800 - the edge that I'm going for 606 00:21:42,844 --> 00:21:45,469 on my blade is more curved in, 607 00:21:45,555 --> 00:21:46,846 like a meat cleaver style. 608 00:21:46,931 --> 00:21:49,682 I think it'll help me some during the chopping test. 609 00:21:49,767 --> 00:21:53,394 The last thing I want is to remove way too much metal 610 00:21:53,479 --> 00:21:55,062 and have a weak spot. 611 00:21:55,148 --> 00:21:57,398 I've come way too far in this competition 612 00:21:57,483 --> 00:21:59,567 to mess up on these final few steps. 613 00:21:59,652 --> 00:22:02,361 - All right, gentlemen, you got 30 minutes remaining. 614 00:22:02,447 --> 00:22:03,612 [exciting rock music] 615 00:22:03,698 --> 00:22:04,947 - I got my crack fixed, 616 00:22:04,991 --> 00:22:06,657 I got my handle on, 617 00:22:06,701 --> 00:22:08,743 and now I'm moving on to the final touches. 618 00:22:08,828 --> 00:22:10,328 I have to make those grooves 619 00:22:10,371 --> 00:22:11,704 in the finger wells of the hunter. 620 00:22:11,789 --> 00:22:16,709 I use a triangular file to actually cut the grooves. 621 00:22:16,794 --> 00:22:20,379 - I'm quite impressed with the work that chris has done. 622 00:22:20,465 --> 00:22:23,049 Round one, we thought he wouldn't even finish. 623 00:22:23,134 --> 00:22:25,551 You stay in the fight all the way till the end. 624 00:22:25,636 --> 00:22:26,969 [upbeat music] 625 00:22:27,055 --> 00:22:29,305 - I don't normally forge a lot of recurves. 626 00:22:29,349 --> 00:22:32,266 They tend to be very difficult to sharpen. 627 00:22:32,352 --> 00:22:34,894 They can get a bit awkward on a grinder. 628 00:22:34,979 --> 00:22:38,647 - It is possible for mike to go too far in sharpening, 629 00:22:38,733 --> 00:22:41,025 make a really, really fine edge, 630 00:22:41,069 --> 00:22:44,403 and get all sorts of problems in the strength test. 631 00:22:44,489 --> 00:22:45,988 [rock music] 632 00:22:46,074 --> 00:22:48,366 - I cannot have any hot spots in this handle 633 00:22:48,409 --> 00:22:50,159 because if it's not comfortable, 634 00:22:50,244 --> 00:22:52,119 it's gonna just cause more stress to your body 635 00:22:52,205 --> 00:22:53,621 that you do not need. 636 00:22:53,706 --> 00:22:56,290 - Brandon's knocking down those handle edges. 637 00:22:56,376 --> 00:22:58,542 Now if you go to one of the finishing belts 638 00:22:58,628 --> 00:23:00,628 and then run it at a slow speed, 639 00:23:00,713 --> 00:23:02,963 it actually does that beautifully and evenly. 640 00:23:03,049 --> 00:23:04,215 - So that's the perfect machine 641 00:23:04,258 --> 00:23:06,133 for what he's doing right now. - Sure. 642 00:23:06,219 --> 00:23:07,802 - And he's using a dremel and an angle grinder. 643 00:23:07,887 --> 00:23:09,095 - Yep. 644 00:23:09,180 --> 00:23:12,181 [dramatic music] 645 00:23:12,266 --> 00:23:13,432 ♪ ♪ 646 00:23:13,518 --> 00:23:15,101 - razor sharp. 647 00:23:15,186 --> 00:23:17,478 - Five, four, three, 648 00:23:17,563 --> 00:23:19,105 two, one! 649 00:23:19,190 --> 00:23:20,689 Turn off your machines! 650 00:23:20,775 --> 00:23:21,899 Put down your tools! 651 00:23:21,943 --> 00:23:24,235 This round is over! 652 00:23:24,278 --> 00:23:26,487 - I'm extremely excited for testing 653 00:23:26,572 --> 00:23:28,072 'cause it wasn't easy on me, 654 00:23:28,116 --> 00:23:29,990 and I don't want the judges to be easy on that. 655 00:23:30,076 --> 00:23:33,327 I want it to come full circle. 656 00:23:33,413 --> 00:23:36,205 - Bladesmiths, welcome to the strength test. 657 00:23:36,290 --> 00:23:37,832 To test the strength and durability 658 00:23:37,917 --> 00:23:39,583 of your edges as well as the overall construction 659 00:23:39,627 --> 00:23:41,168 of your knives, I'll be chopping them 660 00:23:41,254 --> 00:23:43,337 into this canteen and e-tool. 661 00:23:43,423 --> 00:23:45,172 Mike, you're up first. You ready for this? 662 00:23:45,258 --> 00:23:46,132 - Send it. 663 00:23:46,217 --> 00:23:48,008 [dramatic music] 664 00:23:48,094 --> 00:23:51,053 this is definitely the most brutal thing 665 00:23:51,139 --> 00:23:53,264 we're gonna be doing, so I'm super anxious 666 00:23:53,349 --> 00:23:55,057 about what's gonna happen to my blade. 667 00:23:55,143 --> 00:24:02,022 ♪ ♪ 668 00:24:09,532 --> 00:24:11,657 [exhales sharply] 669 00:24:11,742 --> 00:24:13,951 [uneasy music] 670 00:24:13,995 --> 00:24:15,953 - all right, mike. I like this knife. 671 00:24:15,997 --> 00:24:19,707 It's a good reproduction of the recurve utility no. 6. 672 00:24:19,792 --> 00:24:22,501 Your handle--that's a perfectly-sized handle. 673 00:24:22,587 --> 00:24:24,503 Nicely done, but that being said, 674 00:24:24,589 --> 00:24:27,465 it did take a chip, definitely from the canteen. 675 00:24:27,508 --> 00:24:29,508 So didn't come out unscathed, 676 00:24:29,594 --> 00:24:31,177 but it came through this test really well. 677 00:24:31,262 --> 00:24:33,721 So nice job. - Thank you. 678 00:24:33,806 --> 00:24:35,014 - All right, brandon, you're up next. 679 00:24:35,099 --> 00:24:37,308 You ready? - Range is hot, brother. 680 00:24:37,351 --> 00:24:39,268 - All right. 681 00:24:39,353 --> 00:24:41,228 - Going into this test, 682 00:24:41,314 --> 00:24:43,022 I'm really nervous about the chop. 683 00:24:43,107 --> 00:24:45,900 I do not want my spine to break on this knife. 684 00:24:45,985 --> 00:24:49,111 [suspenseful music] 685 00:24:49,197 --> 00:24:56,160 ♪ ♪ 686 00:24:59,957 --> 00:25:01,540 [dramatic music] 687 00:25:01,626 --> 00:25:04,835 - all right, brandon. Well, your finger well spacing 688 00:25:04,921 --> 00:25:06,420 is spread out. 689 00:25:06,506 --> 00:25:07,755 You know, I can't hold this with a fist. 690 00:25:07,840 --> 00:25:09,173 I have to hold it at an angle 691 00:25:09,217 --> 00:25:10,549 in order to get my fingers in all the wells. 692 00:25:10,635 --> 00:25:13,135 So that's an issue, but the knife is in one piece. 693 00:25:13,179 --> 00:25:15,054 Well done. - Thank you, sir. 694 00:25:15,139 --> 00:25:16,263 - All right, chris, you're up. You ready? 695 00:25:16,349 --> 00:25:18,057 - Have at it. - All right. 696 00:25:18,142 --> 00:25:19,642 [tense music] 697 00:25:19,727 --> 00:25:21,352 - the canteen, I don't have too much concern over. 698 00:25:21,437 --> 00:25:23,687 It's the e-tool that I'm worried about 699 00:25:23,731 --> 00:25:26,190 'cause of all the repairs that had to go on to the blade. 700 00:25:26,275 --> 00:25:27,942 I'm concerned about having two knives 701 00:25:28,027 --> 00:25:28,984 at the end of the strength test: 702 00:25:29,028 --> 00:25:30,152 A handle and a blade. 703 00:25:30,238 --> 00:25:35,574 ♪ ♪ 704 00:25:35,660 --> 00:25:37,284 that had to go on to the blade, 705 00:25:37,370 --> 00:25:38,702 I'm concerned about having two knives 706 00:25:38,746 --> 00:25:41,330 at the end of the strength test. 707 00:25:41,374 --> 00:25:44,333 [suspenseful music] 708 00:25:44,377 --> 00:25:47,336 [rock music] 709 00:25:47,421 --> 00:25:54,385 ♪ ♪ 710 00:25:57,682 --> 00:26:00,474 [dramatic music] 711 00:26:00,560 --> 00:26:02,142 - well, chris, I have a feeling 712 00:26:02,228 --> 00:26:04,562 that the mig welding you did close to the edge 713 00:26:04,605 --> 00:26:07,773 without re-quenching has led to a softening of the blade, 714 00:26:07,858 --> 00:26:10,192 'cause there is a deflection right here at edge, 715 00:26:10,278 --> 00:26:11,569 where I struck the metal. 716 00:26:11,654 --> 00:26:13,070 But the rest of the blade held up, 717 00:26:13,114 --> 00:26:14,196 came out the other side in one piece. 718 00:26:14,282 --> 00:26:15,698 So nice job. - Thank you. 719 00:26:15,741 --> 00:26:19,243 [suspenseful music] 720 00:26:19,287 --> 00:26:21,829 - all right, bladesmiths, this is the sharpness test: 721 00:26:21,914 --> 00:26:24,582 The gunpowder bag slice. 722 00:26:24,625 --> 00:26:26,417 To find out how sharp your weapons are, 723 00:26:26,460 --> 00:26:28,168 I will take your weapon and try to cut cleanly 724 00:26:28,254 --> 00:26:30,379 on this canvas bag filled with powder. 725 00:26:30,423 --> 00:26:31,755 Mike, you're up first. You ready for this? 726 00:26:31,799 --> 00:26:34,383 - Let's do it. - Let's do this. 727 00:26:34,468 --> 00:26:37,052 [tense music] 728 00:26:37,138 --> 00:26:44,518 ♪ ♪ 729 00:26:52,612 --> 00:26:53,819 all right, mike, let's talk about 730 00:26:53,904 --> 00:26:56,655 your recurve utility knife no.6. 731 00:26:56,741 --> 00:26:59,908 Your edge took some damage in the beginning, 732 00:26:59,952 --> 00:27:03,579 but it was not a factor at all in slicing the bags. 733 00:27:03,623 --> 00:27:06,498 Overall, sir, it'll cut. 734 00:27:06,584 --> 00:27:08,459 - Thank you. 735 00:27:08,502 --> 00:27:10,169 - All right, brandon, it's your turn, so you ready? 736 00:27:10,254 --> 00:27:12,504 - Sweep and clear, sir. 737 00:27:12,590 --> 00:27:15,549 [dramatic music] 738 00:27:15,635 --> 00:27:22,473 ♪ ♪ 739 00:27:26,145 --> 00:27:27,394 - all right, brandon, let's talk about 740 00:27:27,480 --> 00:27:28,896 your hambone knife here. 741 00:27:28,981 --> 00:27:32,608 On this particular test, it cut deep 742 00:27:32,693 --> 00:27:34,068 and it cut cleanly. 743 00:27:34,153 --> 00:27:36,779 Overall, sir, it'll cut. 744 00:27:36,864 --> 00:27:38,155 - Thank you, sir. 745 00:27:38,240 --> 00:27:39,531 - Chris, you're up. You ready? 746 00:27:39,617 --> 00:27:40,949 - Swing it. 747 00:27:41,035 --> 00:27:44,078 [tense music] 748 00:27:44,163 --> 00:27:51,418 ♪ ♪ 749 00:27:57,134 --> 00:28:00,260 [dramatic music] 750 00:28:00,346 --> 00:28:01,387 - all right, chris, let's talk about 751 00:28:01,472 --> 00:28:03,722 your lamb hunter knife here. 752 00:28:03,808 --> 00:28:06,308 I love the handle because all that stippling 753 00:28:06,352 --> 00:28:10,145 you did there really gives a very nice grip to your blade. 754 00:28:10,231 --> 00:28:12,356 Now the edge itself: 755 00:28:12,441 --> 00:28:14,108 The grind that you have in here 756 00:28:14,193 --> 00:28:16,944 is very wide and obtuse, almost like an ax-head. 757 00:28:17,029 --> 00:28:19,780 It cuts but not deeply because, as you can see, 758 00:28:19,865 --> 00:28:21,073 I can run my finger this way. 759 00:28:21,158 --> 00:28:23,242 It's not as sharp as you would have 760 00:28:23,327 --> 00:28:24,618 with a different grind. 761 00:28:24,704 --> 00:28:27,538 But overall, sir, it did cut. 762 00:28:27,581 --> 00:28:28,872 - Thank you. 763 00:28:28,916 --> 00:28:30,332 [uneasy music] 764 00:28:30,418 --> 00:28:33,168 - bladesmiths, we have finished our american hero knives, 765 00:28:33,254 --> 00:28:35,629 and we've gone through two rounds of grueling testing. 766 00:28:35,715 --> 00:28:37,381 The judges have made a decision, and only two of you 767 00:28:37,425 --> 00:28:39,675 will be moving forward into round three. 768 00:28:39,719 --> 00:28:42,010 And the bladesmith leaving the forge is... 769 00:28:42,096 --> 00:28:44,179 ♪ ♪ 770 00:28:44,223 --> 00:28:45,889 chris. 771 00:28:45,975 --> 00:28:47,433 You're not gonna be going forward. 772 00:28:47,518 --> 00:28:48,976 Doug will tell you why. 773 00:28:49,061 --> 00:28:51,019 - Chris, at the end of the day, 774 00:28:51,063 --> 00:28:53,147 the bags speak for themselves. 775 00:28:53,232 --> 00:28:55,315 The sharpness test, your blade was just outperformed 776 00:28:55,401 --> 00:28:56,608 by the other two knives. 777 00:28:56,694 --> 00:28:58,152 - I understand. 778 00:28:58,237 --> 00:29:00,070 - Chris, you fought very hard, 779 00:29:00,156 --> 00:29:01,613 but unfortunately, I'm gonna have to ask you 780 00:29:01,699 --> 00:29:02,948 to leave the forge floor. 781 00:29:03,033 --> 00:29:04,867 - Gentlemen, it's been an honor. 782 00:29:04,952 --> 00:29:06,034 - You too, brother. 783 00:29:06,078 --> 00:29:07,411 - I completely agree 784 00:29:07,496 --> 00:29:08,954 with the judges' decision on my blade. 785 00:29:09,039 --> 00:29:10,831 It did a lot better than I thought it was gonna do, 786 00:29:10,916 --> 00:29:12,708 but it just didn't cut it in the end. 787 00:29:12,793 --> 00:29:16,545 One thing I'm gonna take away from this experience is, 788 00:29:16,630 --> 00:29:19,131 no matter how hard you think it's gonna be, 789 00:29:19,216 --> 00:29:21,008 you just have to keep going. 790 00:29:21,093 --> 00:29:23,761 ♪ ♪ 791 00:29:23,804 --> 00:29:25,095 [dramatic music] 792 00:29:25,139 --> 00:29:27,848 - mike, brandon, congratulations, guys. 793 00:29:27,933 --> 00:29:29,349 You made it this far. 794 00:29:29,435 --> 00:29:30,517 In round three, we're sending you home 795 00:29:30,603 --> 00:29:32,186 for four days to re-create a weapon 796 00:29:32,271 --> 00:29:33,854 from american military history, 797 00:29:33,939 --> 00:29:37,357 and that weapon is... 798 00:29:37,443 --> 00:29:39,443 The american eagle head saber. 799 00:29:39,528 --> 00:29:43,447 - [laughs] - [exhales, laughs] 800 00:29:43,532 --> 00:29:45,199 - the american eagle head saber 801 00:29:45,284 --> 00:29:46,825 was carried by some of the earliest soldiers 802 00:29:46,911 --> 00:29:48,035 in american military. 803 00:29:48,120 --> 00:29:50,204 Wildly used during the war of 1812, 804 00:29:50,289 --> 00:29:52,247 featuring a long, slightly curved blade, 805 00:29:52,333 --> 00:29:54,917 the weapon was known to inflict deep, lethal cuts. 806 00:29:54,960 --> 00:29:57,753 The iconic sword stands out because of the bald eagle 807 00:29:57,838 --> 00:29:59,379 prominently carved in the pommel. 808 00:29:59,465 --> 00:30:02,049 The eagle became the national bird in 1782 809 00:30:02,134 --> 00:30:04,176 and is sacred among native american tribes. 810 00:30:04,261 --> 00:30:05,844 Before there were any mass-produced 811 00:30:05,930 --> 00:30:08,764 military-issue weapons, these sabers were made 812 00:30:08,849 --> 00:30:11,475 by civilians and prized by u.S. Officers. 813 00:30:11,519 --> 00:30:13,727 There were many variations and styles built, 814 00:30:13,813 --> 00:30:16,772 which makes them highly collectible today. 815 00:30:16,857 --> 00:30:19,149 Gentlemen, pay close attention because you must stay 816 00:30:19,235 --> 00:30:20,609 within the following parameters: 817 00:30:20,694 --> 00:30:23,821 Your blade needs to be between 28 and 30 inches, 818 00:30:23,864 --> 00:30:26,406 and you need to include an eagle head pommel. 819 00:30:26,492 --> 00:30:28,617 - I'm immediately terrified. 820 00:30:28,661 --> 00:30:31,036 I've made one sword before, 821 00:30:31,121 --> 00:30:34,957 and it took much longer than four days to make. 822 00:30:35,042 --> 00:30:37,417 - Bladesmiths, good luck. We'll see you in four days. 823 00:30:37,503 --> 00:30:39,378 ♪ ♪ 824 00:30:39,463 --> 00:30:42,422 [rock music] 825 00:30:42,508 --> 00:30:45,217 - day one--I'm glad to finally be back home 826 00:30:45,302 --> 00:30:47,594 at my home forge, back in my element. 827 00:30:47,680 --> 00:30:49,763 I felt a little caged up down there, 828 00:30:49,849 --> 00:30:51,431 but they set the dog loose, man. 829 00:30:51,517 --> 00:30:53,183 It's time to get some fun stuff going. 830 00:30:53,227 --> 00:30:55,644 Got some heavier truck spring. 831 00:30:55,729 --> 00:30:57,688 It's good steel, so I wanna get it 832 00:30:57,731 --> 00:30:59,523 to where I'm not gonna put any stress fractures 833 00:30:59,608 --> 00:31:01,108 or anything like that in. 834 00:31:01,193 --> 00:31:03,277 Kind of lay it on here, arched up, 835 00:31:03,362 --> 00:31:04,987 start trying to draw it down that way. 836 00:31:05,072 --> 00:31:07,239 ♪ ♪ 837 00:31:07,324 --> 00:31:09,658 by george, I think it works, man. 838 00:31:09,702 --> 00:31:12,744 [upbeat rock music] 839 00:31:12,830 --> 00:31:14,788 - it's day one. 840 00:31:14,874 --> 00:31:17,082 I'm back at my home shop, aka the bakery. 841 00:31:17,167 --> 00:31:21,211 It's called a bakery because I'm the muffin man. 842 00:31:21,255 --> 00:31:23,255 I'm the master baker here. 843 00:31:23,340 --> 00:31:27,885 I'm choosing to use a piece of 5160 spring steel 844 00:31:27,928 --> 00:31:31,346 that's out of an american-made pickup truck. 845 00:31:31,432 --> 00:31:34,766 I'm really focusing on keeping american hardware 846 00:31:34,852 --> 00:31:38,729 in this piece and making it just star-spangled awesome. 847 00:31:38,814 --> 00:31:42,482 First thing I gotta do with this piece of leaf spring is, 848 00:31:42,568 --> 00:31:45,903 I'm gonna start drawing this material down and out. 849 00:31:45,946 --> 00:31:49,156 This particular saber seems to have 850 00:31:49,241 --> 00:31:52,451 a very gentle curve throughout the entire length. 851 00:31:52,536 --> 00:31:56,496 So I start in the middle, and then I slowly work 852 00:31:56,582 --> 00:31:59,833 the front and the backside of the blade. 853 00:31:59,919 --> 00:32:02,336 It's quite the dance. 854 00:32:02,421 --> 00:32:03,587 I like it. 855 00:32:03,672 --> 00:32:05,631 I like it a lot. 856 00:32:05,716 --> 00:32:06,715 [exciting music] 857 00:32:06,800 --> 00:32:08,425 - starting off day two, 858 00:32:08,469 --> 00:32:10,761 trying to get the blade pretty much finished today 859 00:32:10,804 --> 00:32:12,387 so I can start working on my handle. 860 00:32:12,473 --> 00:32:15,349 I got pretty much all my grind on the blade done, 861 00:32:15,434 --> 00:32:18,060 think it's about time for me to get ready for quench. 862 00:32:18,145 --> 00:32:25,025 ♪ ♪ 863 00:32:25,110 --> 00:32:27,861 you'll sing "twinkle, twinkle," man. 864 00:32:27,947 --> 00:32:30,322 For the design of this sword, I wanna integrate 865 00:32:30,407 --> 00:32:32,658 some stuff on to the blade, so I'm gonna go ahead 866 00:32:32,743 --> 00:32:35,202 and do some etching on it, and anything 867 00:32:35,287 --> 00:32:36,578 where you scratch, that's where 868 00:32:36,664 --> 00:32:38,538 the ferric chloride's gonna etch. 869 00:32:38,624 --> 00:32:40,123 I think I'm gonna put some stars on it, 870 00:32:40,167 --> 00:32:42,417 put some lightning bolts to symbolize the storm 871 00:32:42,503 --> 00:32:44,544 that every soldier goes through in his life. 872 00:32:44,630 --> 00:32:47,631 The dates I picked was 1941-- 873 00:32:47,716 --> 00:32:49,216 the day that pearl harbor got hit. 874 00:32:49,301 --> 00:32:51,635 The other day I picked was 1775-- 875 00:32:51,720 --> 00:32:54,346 kind of kicked off the revolutionary war. 876 00:32:54,431 --> 00:32:57,683 I'm stoked at how my sword came out. 877 00:32:57,768 --> 00:32:59,226 [rock music] 878 00:32:59,311 --> 00:33:00,978 - it's the start of day two today. 879 00:33:01,063 --> 00:33:03,188 I'm hoping to have a heat-treated blade 880 00:33:03,273 --> 00:33:04,648 by the end of the day today. 881 00:33:04,733 --> 00:33:07,943 Got the forge heating up, got my oil set up. 882 00:33:08,028 --> 00:33:09,903 And now I'm getting super nervous 883 00:33:09,989 --> 00:33:12,698 'cause it's almost time to quench. 884 00:33:12,783 --> 00:33:14,658 [exhales deeply] 885 00:33:16,328 --> 00:33:20,414 my heart is racing. The pressure's building. 886 00:33:20,499 --> 00:33:22,457 All right. Here we go. 887 00:33:22,543 --> 00:33:27,087 ♪ ♪ 888 00:33:27,172 --> 00:33:29,965 I'm just hoping that this blade has stayed straight. 889 00:33:30,009 --> 00:33:31,675 A kick here or there, 890 00:33:31,719 --> 00:33:33,677 but nothing a grinder can't handle. 891 00:33:33,762 --> 00:33:36,555 It's such a relief to have this quench out of the way, 892 00:33:36,640 --> 00:33:41,143 and now I wanna focus on the details of this handle. 893 00:33:41,228 --> 00:33:43,979 ♪ ♪ 894 00:33:44,064 --> 00:33:46,106 - day four, last day of the build. 895 00:33:46,191 --> 00:33:48,358 I'm making an eagle head saber, 896 00:33:48,444 --> 00:33:51,278 which was used all the way up to the civil war-era times. 897 00:33:51,363 --> 00:33:54,072 Figured I'd go with a civil war-era outfit, 898 00:33:54,158 --> 00:33:55,782 feel it'll give me the spirit I need 899 00:33:55,868 --> 00:33:57,409 to go ahead and finish this sword up. 900 00:33:57,494 --> 00:33:59,286 First order of business I'm gonna go for-- 901 00:33:59,371 --> 00:34:01,955 go ahead, put this pommel on. 902 00:34:02,041 --> 00:34:05,375 ♪ ♪ 903 00:34:05,461 --> 00:34:06,334 [bleep]! 904 00:34:06,378 --> 00:34:07,669 Now that it's broke, 905 00:34:07,755 --> 00:34:09,421 I gotta come up with another plan. 906 00:34:09,506 --> 00:34:10,964 I'm gonna thread up the base of this tang 907 00:34:11,050 --> 00:34:12,758 and try to put another one on. 908 00:34:12,843 --> 00:34:17,345 I should note that I've never really done this before. 909 00:34:17,389 --> 00:34:19,431 That ain't gonna work. 910 00:34:19,516 --> 00:34:21,224 Ended up stripping it out. 911 00:34:21,310 --> 00:34:22,809 There is no way this thing's gonna 912 00:34:22,895 --> 00:34:24,061 lock down tight on its own. 913 00:34:24,104 --> 00:34:26,104 I've gotta come up with something else now. 914 00:34:26,190 --> 00:34:27,481 This is killing me, man. 915 00:34:27,566 --> 00:34:28,774 I'm not sure if I got enough time 916 00:34:28,859 --> 00:34:34,821 to get this unit done. 917 00:34:34,907 --> 00:34:36,656 I'm just gonna go ahead and weld it. 918 00:34:36,742 --> 00:34:40,410 [upbeat rock music] 919 00:34:40,496 --> 00:34:41,578 she's solid. 920 00:34:41,663 --> 00:34:43,413 Look, the weld's not pretty, 921 00:34:43,499 --> 00:34:44,831 but it does its job. 922 00:34:44,917 --> 00:34:47,042 While my wife's inside, I'm gonna go ahead 923 00:34:47,127 --> 00:34:48,919 and cut up one of her tiki torches. 924 00:34:49,004 --> 00:34:51,880 But don't tell nobody 'cause you'll get in trouble too. 925 00:34:51,965 --> 00:34:54,925 ♪ ♪ 926 00:34:54,968 --> 00:34:56,551 [upbeat music] 927 00:34:56,637 --> 00:34:58,053 - it's the start of day four. 928 00:34:58,138 --> 00:35:00,722 I'm definitely feeling the pressure of the final day. 929 00:35:00,808 --> 00:35:03,517 I chose to do the eagle's head pommel 930 00:35:03,602 --> 00:35:05,268 out of scrap steel. 931 00:35:05,354 --> 00:35:08,605 The bald eagle is a very important piece 932 00:35:08,690 --> 00:35:10,607 of this blade to me. 933 00:35:10,692 --> 00:35:12,734 I'm a very patriotic person, 934 00:35:12,820 --> 00:35:16,947 so I'm really just dialed into getting this looking right. 935 00:35:17,032 --> 00:35:18,490 [sighs] okay. 936 00:35:18,575 --> 00:35:22,369 I'm going for a black op-themed sword, 937 00:35:22,454 --> 00:35:25,413 so I'm darkening the blade and all my hardware. 938 00:35:25,499 --> 00:35:28,291 I'm pretty happy with the look of the flat black. 939 00:35:28,377 --> 00:35:31,128 The eagle kind of looks like a crow now, 940 00:35:31,213 --> 00:35:33,713 but I'm super happy that I was able 941 00:35:33,799 --> 00:35:35,882 to make a sword in four days. 942 00:35:35,968 --> 00:35:37,217 Whew! 943 00:35:37,302 --> 00:35:39,136 [tense music] 944 00:35:39,221 --> 00:35:41,596 - veterans, welcome back to the forge. 945 00:35:41,640 --> 00:35:43,306 You guys have had four days back at your home forges 946 00:35:43,392 --> 00:35:45,934 to work on your renditions of the eagle head saber. 947 00:35:45,978 --> 00:35:49,062 Now before we get into it, I wanna say as a veteran, 948 00:35:49,148 --> 00:35:50,480 thank you guys both for your service. 949 00:35:50,566 --> 00:35:52,732 But we're here for your saber, so, mike, 950 00:35:52,818 --> 00:35:54,151 tell us about your blade. 951 00:35:54,194 --> 00:35:55,110 [dramatic music] 952 00:35:55,195 --> 00:35:57,779 - it's acid-washed, 5160, 953 00:35:57,865 --> 00:35:59,865 out of an american pickup truck. 954 00:35:59,950 --> 00:36:02,617 The stirrup guard is all mild steel, 955 00:36:02,703 --> 00:36:05,412 and it's african blackwood for the handle. 956 00:36:05,497 --> 00:36:07,664 Sort of went for a black ops theme. 957 00:36:07,749 --> 00:36:09,124 - Well, thank you very much. 958 00:36:09,209 --> 00:36:10,125 You put a ton of work into that. 959 00:36:10,210 --> 00:36:11,459 Brandon, tell me about your work. 960 00:36:11,545 --> 00:36:13,461 ♪ ♪ 961 00:36:13,547 --> 00:36:15,046 - I went ahead and made my saber 962 00:36:15,132 --> 00:36:17,215 out of 5160 steel. 963 00:36:17,301 --> 00:36:19,759 For the handle, I integrated purpleheart wood 964 00:36:19,845 --> 00:36:21,720 to symbolize the purple heart award. 965 00:36:21,805 --> 00:36:24,723 On the blade, I etched 13 stars down the blade 966 00:36:24,808 --> 00:36:28,185 to symbolize the 13 stars on the medal of honor award. 967 00:36:28,228 --> 00:36:30,353 - There is a lot of detail in there, man. 968 00:36:30,439 --> 00:36:33,899 So the only way to figure out which one of these sabers 969 00:36:33,984 --> 00:36:36,943 is gonna end up on top is to put 'em through three tests. 970 00:36:37,029 --> 00:36:38,445 We're gonna put you through a strength test, 971 00:36:38,530 --> 00:36:40,947 a sharpness test, and up first, the infamous 972 00:36:41,033 --> 00:36:42,616 doug marcaida keal test. 973 00:36:42,701 --> 00:36:45,869 [ominous music] 974 00:36:45,954 --> 00:36:49,331 - all right, bladesmiths, welcome to the keal test. 975 00:36:49,416 --> 00:36:50,415 ♪ ♪ 976 00:36:50,500 --> 00:36:52,083 let's find out what kind of lethal damage 977 00:36:52,169 --> 00:36:53,293 your sabers will do. 978 00:36:53,378 --> 00:36:54,878 I will take your weapon and deliver some 979 00:36:54,963 --> 00:36:59,049 lethal blows and slashes on this ballistics dummy. 980 00:36:59,134 --> 00:37:01,009 All right, mike, your turn, so you ready? 981 00:37:01,053 --> 00:37:03,053 - Let's do it. 982 00:37:03,096 --> 00:37:04,804 [dramatic music] 983 00:37:04,890 --> 00:37:08,892 the ballistics dummy is just a brutal test. 984 00:37:08,936 --> 00:37:11,853 A simple shock could break it apart. 985 00:37:11,939 --> 00:37:15,023 ♪ ♪ 986 00:37:15,067 --> 00:37:18,026 [rock music] 987 00:37:18,111 --> 00:37:20,987 ♪ ♪ 988 00:37:21,073 --> 00:37:22,197 phew. 989 00:37:22,282 --> 00:37:29,412 ♪ ♪ 990 00:37:35,254 --> 00:37:37,587 - all right, mike, let's talk about your saber here. 991 00:37:37,631 --> 00:37:40,423 Your edge is razor sharp, 992 00:37:40,509 --> 00:37:42,425 and because it's a lighter sword, 993 00:37:42,511 --> 00:37:46,179 I can really maneuver the blade to deeper cuts. 994 00:37:46,265 --> 00:37:50,141 Overall, sir, your saber will keal. 995 00:37:50,227 --> 00:37:52,060 - Thank you. 996 00:37:52,145 --> 00:37:53,770 - All right, brandon, it's your turn, so you ready? 997 00:37:53,855 --> 00:37:55,939 - Oh, let's see what he's made of. 998 00:37:55,983 --> 00:37:57,607 [tense music] 999 00:37:57,651 --> 00:38:00,902 I was so excited to see jelly bob sitting up there. 1000 00:38:00,988 --> 00:38:02,070 I wanna see stuff break. 1001 00:38:02,155 --> 00:38:03,947 I wanna see stuff get slashed up. 1002 00:38:04,032 --> 00:38:05,407 I wanna see heads roll. I wanna see 1003 00:38:05,492 --> 00:38:07,409 all kinds of fun stuff and things, man. 1004 00:38:07,494 --> 00:38:10,287 ♪ ♪ 1005 00:38:10,372 --> 00:38:13,581 [upbeat rock music] 1006 00:38:13,667 --> 00:38:20,630 ♪ ♪ 1007 00:38:21,758 --> 00:38:23,591 - [grunts] 1008 00:38:23,677 --> 00:38:28,638 ♪ ♪ 1009 00:38:31,226 --> 00:38:33,810 [both laugh] 1010 00:38:33,854 --> 00:38:36,438 [dramatic music] 1011 00:38:36,523 --> 00:38:38,315 ♪ ♪ 1012 00:38:38,400 --> 00:38:39,858 all right, brandon, let's talk about your weapon here. 1013 00:38:39,943 --> 00:38:41,359 It's a heavy beast. 1014 00:38:41,445 --> 00:38:45,322 The added weight delivers a very deep cut 1015 00:38:45,407 --> 00:38:48,366 into the ballistics dummy, but even wielding it, 1016 00:38:48,452 --> 00:38:51,619 I have to actually take pause to be able to swing again. 1017 00:38:51,663 --> 00:38:53,455 [grunts] 1018 00:38:53,540 --> 00:38:55,165 ♪ ♪ 1019 00:38:55,250 --> 00:38:59,961 but overall, sir, your weapon will keal. 1020 00:39:00,047 --> 00:39:01,838 - Thank you, sir. 1021 00:39:01,882 --> 00:39:05,508 [tense music] 1022 00:39:05,552 --> 00:39:07,010 - all right, gentlemen, it's time 1023 00:39:07,095 --> 00:39:08,803 for the strength test. 1024 00:39:08,847 --> 00:39:11,181 To test the strength and overall construction 1025 00:39:11,266 --> 00:39:14,059 of your blade, I'll be swinging into our muskets here. 1026 00:39:14,144 --> 00:39:16,770 Now, you might think this is an insane test, 1027 00:39:16,855 --> 00:39:18,063 and it is an insane test, but if you notice, 1028 00:39:18,148 --> 00:39:20,857 that bottom barrel there has four nicks in it. 1029 00:39:20,901 --> 00:39:22,817 That's from my saber, the saber that was displayed. 1030 00:39:22,903 --> 00:39:24,819 I'm not gonna ask your weapons to go through anything 1031 00:39:24,905 --> 00:39:26,613 I don't put my own weapons through, 1032 00:39:26,698 --> 00:39:28,365 and I expect you guys to pass. 1033 00:39:28,450 --> 00:39:30,200 All right, mike, you're up. You ready? 1034 00:39:30,243 --> 00:39:31,659 - [exhales] ooh, let's-- 1035 00:39:31,745 --> 00:39:34,037 - oh, come on! It's just gun barrels. 1036 00:39:34,122 --> 00:39:35,705 [laughter] 1037 00:39:35,749 --> 00:39:38,208 [dramatic music] 1038 00:39:38,293 --> 00:39:40,335 - the strength test looks brutal. 1039 00:39:40,379 --> 00:39:44,130 This is just stuff you don't normally test blades on. 1040 00:39:44,216 --> 00:39:47,384 It could ultimately shatter in one swing. 1041 00:39:47,469 --> 00:39:49,677 [exhales sharply] let's see. 1042 00:39:49,763 --> 00:39:56,393 ♪ ♪ 1043 00:39:56,478 --> 00:39:58,812 it could ultimately shatter in one swing. 1044 00:39:58,897 --> 00:40:01,147 [exhales sharply] let's see. 1045 00:40:01,233 --> 00:40:04,359 [rock music] 1046 00:40:04,444 --> 00:40:11,408 ♪ ♪ 1047 00:40:13,578 --> 00:40:14,869 [exhales sharply] 1048 00:40:14,955 --> 00:40:17,414 - all right, mike, your weapon is light enough 1049 00:40:17,499 --> 00:40:21,209 that it is very easy to control. 1050 00:40:21,294 --> 00:40:22,877 Your blade came through it well. 1051 00:40:22,963 --> 00:40:25,130 It took some chips, but all in all, 1052 00:40:25,215 --> 00:40:26,714 your weapon is still in one piece. 1053 00:40:26,800 --> 00:40:28,550 It's still solid, held up beautifully. 1054 00:40:28,635 --> 00:40:30,510 Nicely done. - Thank you. 1055 00:40:30,595 --> 00:40:31,636 - Brandon, you ready? 1056 00:40:31,721 --> 00:40:33,221 - Oh, let's do stuff and things, man. 1057 00:40:33,306 --> 00:40:34,681 - [chuckles] 1058 00:40:34,766 --> 00:40:38,309 [upbeat rock music] 1059 00:40:38,395 --> 00:40:45,400 ♪ ♪ 1060 00:40:49,489 --> 00:40:52,532 [clinking] 1061 00:40:52,617 --> 00:40:55,493 [dramatic music] 1062 00:40:55,579 --> 00:40:57,495 ♪ ♪ 1063 00:40:57,581 --> 00:41:01,124 all right, brandon, your blade has not lost 1064 00:41:01,209 --> 00:41:03,585 any of its edge, and it certainly held up. 1065 00:41:03,670 --> 00:41:06,421 So that's great, but the biggest issue 1066 00:41:06,506 --> 00:41:09,174 is that that's just snapped clean off. 1067 00:41:09,259 --> 00:41:10,258 - Yeah. 1068 00:41:10,302 --> 00:41:11,676 - How was your handle constructed? 1069 00:41:11,761 --> 00:41:13,386 - Once I fit the blade guard on, 1070 00:41:13,472 --> 00:41:16,181 I stacked leather coins up inside the copper sheath, 1071 00:41:16,266 --> 00:41:19,267 put them on epoxy, and then kind of hammered 1072 00:41:19,311 --> 00:41:20,477 on the disk on the back. 1073 00:41:20,562 --> 00:41:22,270 - So basically, this eagle head pommel 1074 00:41:22,314 --> 00:41:24,481 is your only mechanical connection. 1075 00:41:24,524 --> 00:41:26,232 - Yes. - Okay. 1076 00:41:32,657 --> 00:41:34,699 - Okay. 1077 00:41:34,784 --> 00:41:37,160 [tense music] 1078 00:41:37,245 --> 00:41:39,954 brandon, you brought us an absolutely beautiful blade. 1079 00:41:40,040 --> 00:41:41,664 It's very clear you put a lot of heart 1080 00:41:41,750 --> 00:41:43,458 and a lot of thought into it, but being that your pommel 1081 00:41:43,543 --> 00:41:45,460 is the only thing holding the blade together, 1082 00:41:45,545 --> 00:41:47,378 we consider that a catastrophic failure 1083 00:41:47,464 --> 00:41:49,047 and cannot move forward in the testing. 1084 00:41:49,132 --> 00:41:50,965 With that reason, I'm gonna have to ask you 1085 00:41:51,051 --> 00:41:52,509 to leave the forge. Thanks for what you did 1086 00:41:52,552 --> 00:41:54,302 for our country. - Thank you, brother. 1087 00:41:54,387 --> 00:41:57,055 Been a pleasure, gentlemen. 1088 00:41:57,140 --> 00:41:59,265 Overall, it was an amazing experience 1089 00:41:59,351 --> 00:42:00,642 building this weapon. 1090 00:42:00,727 --> 00:42:02,685 I'm happy about how my blade turned out. 1091 00:42:02,771 --> 00:42:04,312 I mean, the pommel broke off, 1092 00:42:04,397 --> 00:42:06,064 but it didn't take no blade damage. 1093 00:42:06,149 --> 00:42:08,233 It's still got a couple more battles left in her. 1094 00:42:08,318 --> 00:42:11,069 ♪ ♪ 1095 00:42:11,154 --> 00:42:12,529 - all right, mike, congratulations. 1096 00:42:12,614 --> 00:42:14,614 You are the "forged in fire" champion, 1097 00:42:14,699 --> 00:42:17,325 and you'll be heading out of here a little bit richer 1098 00:42:17,410 --> 00:42:19,327 with a $10,000 check in your pocket. 1099 00:42:19,412 --> 00:42:22,121 So well done. - Good job, man. 1100 00:42:22,207 --> 00:42:23,998 - I am to the moon. 1101 00:42:24,084 --> 00:42:25,708 I didn't think I would make it to the final round, 1102 00:42:25,794 --> 00:42:27,835 let alone come out on top. 1103 00:42:27,921 --> 00:42:30,421 I'm the newest "forged in fire" champion, 1104 00:42:30,507 --> 00:42:32,423 and at home, I'm the muffin man. 1105 00:42:32,509 --> 00:42:34,008 So, I guess, everybody out there, 1106 00:42:34,094 --> 00:42:36,135 you're--you're looking at a tough muff. 1107 00:42:36,221 --> 00:42:39,180 [rock music] 1108 00:42:39,266 --> 00:42:42,976 ♪ ♪