1 00:00:05,006 --> 00:00:07,631 [dramatic music] 2 00:00:07,717 --> 00:00:11,010 ♪ ♪ 3 00:00:11,095 --> 00:00:13,721 [rock music] 4 00:00:13,806 --> 00:00:15,305 - my name is bryan dana custance. 5 00:00:15,391 --> 00:00:16,890 I am 41 years old. 6 00:00:16,976 --> 00:00:18,809 When I was 14 years old, 7 00:00:18,894 --> 00:00:20,811 I made a screwdriver, 8 00:00:20,896 --> 00:00:22,479 and as soon as I saw a hammer hit hot metal, 9 00:00:22,565 --> 00:00:24,648 there was never any coming back. 10 00:00:24,734 --> 00:00:26,358 ♪ ♪ 11 00:00:26,402 --> 00:00:27,651 - I'm evan seahawk. 12 00:00:27,737 --> 00:00:30,320 Full-time, I am a graphic designer. 13 00:00:30,406 --> 00:00:33,032 I work a normal nine to five job. 14 00:00:33,117 --> 00:00:36,285 I come home, pour into my family, 15 00:00:36,370 --> 00:00:37,953 put the kids to bed, 16 00:00:38,039 --> 00:00:39,872 and then from 10:30 till 3:00 in the morning, 17 00:00:39,957 --> 00:00:41,415 that's my forge time. 18 00:00:41,500 --> 00:00:42,833 ♪ ♪ 19 00:00:42,918 --> 00:00:44,710 - my name is walter baranowski. 20 00:00:44,795 --> 00:00:46,670 I'm a fourth generation metal worker. 21 00:00:46,756 --> 00:00:50,132 My grandfather in the philippians was a bladesmith, 22 00:00:50,217 --> 00:00:52,676 my father was a welder, 23 00:00:52,762 --> 00:00:54,720 and there was always, like, a deep calling. 24 00:00:54,764 --> 00:00:57,473 I started making knives when I was 18 25 00:00:57,558 --> 00:00:59,266 and haven't stopped since. 26 00:00:59,351 --> 00:01:00,851 ♪ ♪ 27 00:01:00,936 --> 00:01:03,228 - my name's paul destefano, I'm 26 years old, 28 00:01:03,314 --> 00:01:05,522 and I'm an emt for the new york city fire department. 29 00:01:05,608 --> 00:01:08,692 For me, bladesmithing is purely an artistic outlet. 30 00:01:08,778 --> 00:01:12,029 I like blades as forms of art 31 00:01:12,114 --> 00:01:14,073 because it's brutal, but it can also be elegant. 32 00:01:14,158 --> 00:01:16,158 That's kinda something you don't see often 33 00:01:16,243 --> 00:01:18,035 in other forms of art. 34 00:01:18,120 --> 00:01:19,286 [dramatic music] 35 00:01:19,371 --> 00:01:20,537 - gentlemen, welcome to the forge. 36 00:01:20,623 --> 00:01:22,915 Today you're about to take part 37 00:01:23,000 --> 00:01:25,542 in a forging competition unlike any other. 38 00:01:25,628 --> 00:01:27,002 We're gonna have three rounds of competition. 39 00:01:27,088 --> 00:01:28,087 At the end of each round, 40 00:01:28,172 --> 00:01:29,213 I'm gonna ask you to present your work 41 00:01:29,256 --> 00:01:30,964 to our panel of expert judges. 42 00:01:31,050 --> 00:01:32,257 Those judges are 43 00:01:32,301 --> 00:01:35,260 two-time "forged in fire" champion ben abbott. 44 00:01:35,346 --> 00:01:37,554 Next we got historic weapons recreation specialist 45 00:01:37,640 --> 00:01:38,722 dave baker. 46 00:01:38,808 --> 00:01:40,641 And edged weapon specialist 47 00:01:40,726 --> 00:01:42,559 doug marcaida. 48 00:01:42,645 --> 00:01:44,520 And you guys are gonna be competing head to head 49 00:01:44,605 --> 00:01:46,939 for the coveted title of "forged in fire" champion 50 00:01:47,024 --> 00:01:49,233 and a check for $10,000. 51 00:01:49,318 --> 00:01:50,984 Today in the forge, we're gonna put a twist 52 00:01:51,070 --> 00:01:53,612 on one of our classic forging competitions. 53 00:01:53,697 --> 00:01:55,739 You guys see you've a cloth in front of you. 54 00:01:55,825 --> 00:01:58,575 Why don't you go ahead and pull those off for me? 55 00:01:58,661 --> 00:01:59,910 ♪ ♪ 56 00:01:59,995 --> 00:02:01,328 you guys have a choice to make. 57 00:02:01,413 --> 00:02:02,663 You either make your blades 58 00:02:02,748 --> 00:02:04,373 out of that big suspension bridge cable 59 00:02:04,458 --> 00:02:06,083 or the small piano wire. 60 00:02:06,168 --> 00:02:08,418 Each one of those is a viable option. 61 00:02:08,504 --> 00:02:10,170 They both have really good high carbon steel, 62 00:02:10,256 --> 00:02:12,965 but they'll different methods to make your blades. 63 00:02:13,008 --> 00:02:14,842 Regardless of what steel you guys choose, 64 00:02:14,927 --> 00:02:16,552 I want you make signature blades 65 00:02:16,637 --> 00:02:19,930 in your signature styles between 13 and 15 inches. 66 00:02:20,015 --> 00:02:22,432 - I'm considering the piano wire. 67 00:02:22,518 --> 00:02:23,976 I'm looking at, and like, 68 00:02:24,061 --> 00:02:25,310 I don't think there's enough here 69 00:02:25,396 --> 00:02:26,937 to really make what I want. 70 00:02:27,022 --> 00:02:30,691 I know there's too much with the other one. 71 00:02:30,776 --> 00:02:32,734 That is gonna be tough. 72 00:02:32,820 --> 00:02:34,111 - Now, round two of the competition, 73 00:02:34,196 --> 00:02:35,821 you're gonna be adding handles to your blades, 74 00:02:35,865 --> 00:02:37,489 turning them into fully functioning weapons, 75 00:02:37,575 --> 00:02:39,658 and we're gonna test for strength and durability 76 00:02:39,743 --> 00:02:41,618 in an animal horn chop 77 00:02:41,704 --> 00:02:45,289 and check your edge retention in a water tube slice. 78 00:02:45,332 --> 00:02:47,040 All right, bladesmiths, work hard, 79 00:02:47,126 --> 00:02:48,584 but keep your eyes on the clock. 80 00:02:48,669 --> 00:02:51,086 You will only have three hours to complete this challenge. 81 00:02:51,172 --> 00:02:54,298 Your time starts now. 82 00:02:54,383 --> 00:02:56,300 ♪ ♪ 83 00:02:56,343 --> 00:02:57,634 we got a big cable out there, 84 00:02:57,720 --> 00:02:59,970 and we've got a spool of smaller wire. 85 00:03:00,055 --> 00:03:01,972 What the different steps you guys would take 86 00:03:02,016 --> 00:03:03,640 with each different option? 87 00:03:03,726 --> 00:03:06,351 The big cable, you weld both ends together, 88 00:03:06,395 --> 00:03:08,020 heat them up, tighten the twist 89 00:03:08,063 --> 00:03:09,646 so the things are more bound together, 90 00:03:09,732 --> 00:03:11,356 get it up to a forge welding temperature, 91 00:03:11,442 --> 00:03:13,609 and pack everything together. - Okay. 92 00:03:13,694 --> 00:03:15,152 - Then with the piano wire, 93 00:03:15,237 --> 00:03:18,238 you're gonna pack it in a canister with 1095 powder 94 00:03:18,324 --> 00:03:20,157 and do a typical canister weld. 95 00:03:20,242 --> 00:03:21,909 - I'm looking at the two cables, 96 00:03:21,994 --> 00:03:24,119 and I'm the big cable's gonna be easier 97 00:03:24,205 --> 00:03:26,371 to get a 13 to 15 inch blade. 98 00:03:26,415 --> 00:03:28,498 I'm scrubbing it down with acetone first 99 00:03:28,584 --> 00:03:31,251 to get much of the grease and gunk out of there as I can. 100 00:03:31,337 --> 00:03:34,213 - We've seen a lot of times where cleaning upfront 101 00:03:34,256 --> 00:03:36,215 saves you restarting later. 102 00:03:38,177 --> 00:03:39,426 ♪ ♪ 103 00:03:39,511 --> 00:03:40,969 - I decide to go with the bigger cable 104 00:03:41,055 --> 00:03:42,554 rather than the piano wire. 105 00:03:42,640 --> 00:03:45,349 Piano wire's not something I have a lot of experience with. 106 00:03:45,434 --> 00:03:46,600 ♪ ♪ 107 00:03:46,685 --> 00:03:48,977 I probably don't need all of these pieces, 108 00:03:49,063 --> 00:03:51,063 so I'm gonna pull two of them out. 109 00:03:51,148 --> 00:03:54,858 - Here's the issue I have with what walter's doing. 110 00:03:54,944 --> 00:03:56,193 With cable damascus, 111 00:03:56,237 --> 00:03:57,653 you usually have little frayed cables 112 00:03:57,738 --> 00:03:59,488 that will spread out while you're welding. 113 00:03:59,573 --> 00:04:01,740 You need a bit of waste metal 114 00:04:01,825 --> 00:04:03,325 that you can get rid of, 115 00:04:03,410 --> 00:04:06,662 and when you have just a minimal amount of material, 116 00:04:06,747 --> 00:04:08,038 it turns into an issue. 117 00:04:08,123 --> 00:04:10,040 ♪ ♪ 118 00:04:10,125 --> 00:04:12,334 - I'm gonna work down each one of these smaller pieces 119 00:04:12,419 --> 00:04:13,502 into its own billet, 120 00:04:13,587 --> 00:04:14,920 make a stack, 121 00:04:14,964 --> 00:04:17,047 forge weld them together. 122 00:04:17,132 --> 00:04:18,507 Bladesmithing runs in my blood. 123 00:04:18,592 --> 00:04:21,885 I wanna bring pride to my family name, 124 00:04:21,971 --> 00:04:23,720 and this is something I love to do. 125 00:04:23,806 --> 00:04:25,013 ♪ ♪ 126 00:04:25,099 --> 00:04:27,140 - no, cable. - Yeah, cable, cable. 127 00:04:27,226 --> 00:04:28,558 - Cable. 128 00:04:28,644 --> 00:04:30,060 - Nobody wants smaller wire. Why do you think that is? 129 00:04:30,145 --> 00:04:32,813 - If you haven't done a canister, it's risky. 130 00:04:32,898 --> 00:04:34,940 - I didn't even look at the piano wire. 131 00:04:35,025 --> 00:04:37,192 I've made cable damascus before. 132 00:04:37,278 --> 00:04:40,070 Big thick steel cable, this is what I'm gonna have to go with. 133 00:04:40,155 --> 00:04:41,947 Everyone's breaking down this cable 134 00:04:42,032 --> 00:04:44,741 to where they have these small little strands, 135 00:04:44,827 --> 00:04:46,493 but I'm just gonna use the whole thing. 136 00:04:46,578 --> 00:04:48,245 - Paul is doing it the way I would do it. 137 00:04:48,330 --> 00:04:49,955 It's just weld both the ends up 138 00:04:49,999 --> 00:04:51,164 so they don't come unfurled, 139 00:04:51,250 --> 00:04:53,083 toss it into the forge. 140 00:04:53,168 --> 00:04:54,459 - I'm trying to keep it thick 141 00:04:54,545 --> 00:04:56,336 so that when I go into the grinder, 142 00:04:56,422 --> 00:04:57,796 I can dig deep 143 00:04:57,840 --> 00:05:00,090 and carve out any bad welds 144 00:05:00,175 --> 00:05:01,925 along the edge of the knife. 145 00:05:02,011 --> 00:05:03,760 - Good time management it seems too. 146 00:05:03,846 --> 00:05:05,429 Every time he puts it back into the forge, 147 00:05:05,514 --> 00:05:07,431 he's running out and working on a design. 148 00:05:07,516 --> 00:05:09,891 - I wanna just make a simple camp knife, 149 00:05:09,977 --> 00:05:11,518 and I'm on the clock, 150 00:05:11,603 --> 00:05:14,271 so I just wanna make something solid that I know will perform. 151 00:05:14,356 --> 00:05:17,941 - I've got the big cable apart. 152 00:05:18,027 --> 00:05:20,485 What I'm trying to do by welding the top and the bottom 153 00:05:20,529 --> 00:05:23,905 is keep it in one piece so that when I start to twist, 154 00:05:23,991 --> 00:05:25,574 it's not gonna fly apart. 155 00:05:25,659 --> 00:05:27,826 If there's a weld flaw 156 00:05:27,911 --> 00:05:30,996 and something goes wrong in the steel, 157 00:05:31,081 --> 00:05:32,956 not gonna be good for me 158 00:05:33,042 --> 00:05:35,542 in any way, shape, or form. 159 00:05:35,627 --> 00:05:37,294 - What twisting actually is doing 160 00:05:37,379 --> 00:05:39,004 is applying a pressure from all sides 161 00:05:39,089 --> 00:05:40,964 and top and bottom all at the same time. 162 00:05:41,050 --> 00:05:45,635 ♪ ♪ 163 00:05:45,721 --> 00:05:47,304 - I'm twisting my cables. 164 00:05:47,389 --> 00:05:50,140 I wanna get it twisted up as tight as I absolutely can. 165 00:05:50,225 --> 00:05:52,100 ♪ ♪ 166 00:05:52,186 --> 00:05:53,518 [grunts] 167 00:05:53,604 --> 00:05:55,812 the material is much harder to twist than I expected. 168 00:05:55,898 --> 00:05:57,272 ♪ ♪ 169 00:05:57,358 --> 00:05:59,983 as I'm trying to get my billet correctly compact, 170 00:06:00,069 --> 00:06:02,152 and I realize that my twist isn't tight enough. 171 00:06:02,237 --> 00:06:05,697 If I cannot get these strands compacted together, 172 00:06:05,783 --> 00:06:07,366 I won't have anything to show the judges. 173 00:06:07,409 --> 00:06:09,868 I've gotta try to drive everything together 174 00:06:09,953 --> 00:06:12,537 by smacking the billet down on the floor. 175 00:06:12,623 --> 00:06:14,998 Hoping that my welds will be better. 176 00:06:15,084 --> 00:06:17,834 Looks like it's compressing my material just fine, 177 00:06:17,920 --> 00:06:19,044 so I'm feeling pretty good. 178 00:06:22,591 --> 00:06:25,592 - You see all the untwisted cable by paul's work deck? 179 00:06:25,677 --> 00:06:26,760 He doesn't need that area at all. 180 00:06:26,845 --> 00:06:28,178 He could cut the whole thing off, 181 00:06:28,222 --> 00:06:29,513 and he's got plenty of steel. 182 00:06:29,598 --> 00:06:32,140 - All right. Paul is gonna go choppy choppy. 183 00:06:32,226 --> 00:06:33,934 - There you go. 184 00:06:34,019 --> 00:06:36,144 - [as arnold schwarzenegger] get your billet to the chopper! 185 00:06:36,230 --> 00:06:37,437 - With cable damascus, 186 00:06:37,523 --> 00:06:39,689 the outside is always gonna have bad welds 187 00:06:39,775 --> 00:06:40,857 no matter what. 188 00:06:40,943 --> 00:06:43,360 So I want to grind most of that away. 189 00:06:43,445 --> 00:06:45,278 - I don't know why he's grinding. 190 00:06:45,364 --> 00:06:47,572 Come on, paul, why don't you hammer it into a shape? 191 00:06:47,658 --> 00:06:50,200 Draw that out to where you want it, then grind the edges. 192 00:06:50,285 --> 00:06:52,786 It's a step you don't need to take right now. 193 00:06:52,871 --> 00:06:54,538 - It doesn't matter how long it takes 194 00:06:54,581 --> 00:06:55,831 grinding all the welds out, 195 00:06:55,916 --> 00:06:57,416 if I don't do it, 196 00:06:57,501 --> 00:07:01,169 I won't have a knife that can pass any performance test. 197 00:07:01,255 --> 00:07:02,462 - One hour down! 198 00:07:02,506 --> 00:07:05,340 You've got two hours remaining on the clock! 199 00:07:05,426 --> 00:07:06,633 [dramatic music] 200 00:07:06,718 --> 00:07:08,051 - I keep looking at these bars, 201 00:07:08,137 --> 00:07:09,469 and I'm really telling myself, 202 00:07:09,555 --> 00:07:12,013 "dude, you don't have enough steel." 203 00:07:12,099 --> 00:07:15,350 aw, man, I'm freaking out. 204 00:07:15,436 --> 00:07:16,560 I ain't got time to sit around 205 00:07:16,645 --> 00:07:18,395 and think about what the heck I'm doing. 206 00:07:18,480 --> 00:07:21,690 I decide I'm gonna go with making another bar. 207 00:07:21,775 --> 00:07:24,317 One more. Do one more. 208 00:07:24,403 --> 00:07:26,194 - Walter seems to be the only one 209 00:07:26,280 --> 00:07:28,572 that doesn't have one working billet now. 210 00:07:28,657 --> 00:07:30,699 - He's created some issues for himself for sure. 211 00:07:30,784 --> 00:07:32,492 [rock music] 212 00:07:32,578 --> 00:07:33,535 - whoo! 213 00:07:33,620 --> 00:07:36,037 I love taking this piece 214 00:07:36,123 --> 00:07:38,290 of lifeless junk 215 00:07:38,375 --> 00:07:41,626 and making a tool that's gonna be around 216 00:07:41,712 --> 00:07:43,753 hundreds of years after I'm gone. 217 00:07:43,839 --> 00:07:46,923 I got started when my wife got me a lesson 218 00:07:47,009 --> 00:07:48,550 with a master bladesmith, 219 00:07:48,635 --> 00:07:51,094 and that's a decision 220 00:07:51,180 --> 00:07:52,429 she's regretted ever since. 221 00:07:52,514 --> 00:07:55,182 It's solid, it's looking good. 222 00:07:55,267 --> 00:07:57,058 So I'm moving over to the chop saw, 223 00:07:57,144 --> 00:07:58,810 and what I need to do 224 00:07:58,854 --> 00:08:00,604 is preform my tip. 225 00:08:00,689 --> 00:08:03,356 It's gonna be a big time saver. 226 00:08:03,442 --> 00:08:05,942 - Evan's starting to get some shape going on. 227 00:08:05,986 --> 00:08:08,612 Bryan's well on his way. 228 00:08:08,697 --> 00:08:12,073 - I'm forging a fighter with an indexed handle 229 00:08:12,159 --> 00:08:14,159 and an upswept blade. 230 00:08:14,244 --> 00:08:16,328 I'm hammering the tip into shape, 231 00:08:16,413 --> 00:08:18,788 and I'm gonna leave the rest of it for big blu. 232 00:08:18,874 --> 00:08:20,123 ♪ ♪ 233 00:08:20,209 --> 00:08:22,000 - bryan's got about the largest piece of steel 234 00:08:22,044 --> 00:08:23,293 out here right now. 235 00:08:23,378 --> 00:08:24,878 - Honestly, I don't know that his piece of steel 236 00:08:24,963 --> 00:08:28,298 is any larger in volume than paul's is, 237 00:08:28,383 --> 00:08:30,383 but paul hasn't drawn his out at all. 238 00:08:30,469 --> 00:08:32,511 - It must be disconcerting to watch 239 00:08:32,596 --> 00:08:34,804 paul really stare into his billet 240 00:08:34,848 --> 00:08:35,931 that much when your grinding. 241 00:08:36,016 --> 00:08:37,557 I'm like, "what are you seeing?" 242 00:08:37,643 --> 00:08:39,726 - I have no idea how long I've been standing here grinding, 243 00:08:39,811 --> 00:08:41,853 but if I don't get all these bad welds out, 244 00:08:41,897 --> 00:08:44,940 they would just show up all along the knife. 245 00:08:45,025 --> 00:08:46,316 So I have to do what I have to do. 246 00:08:46,401 --> 00:08:48,485 - I don't think he's finished forge welding yet. 247 00:08:48,570 --> 00:08:49,819 - It's time to throw it back into the forge. 248 00:08:49,905 --> 00:08:51,238 Something's not welded in there. 249 00:08:51,323 --> 00:08:52,822 - Yep. 250 00:08:52,908 --> 00:08:54,824 [clanking] - you all right? 251 00:08:54,910 --> 00:08:57,994 - I'm chasing bad welds for, like, half an hour. 252 00:08:58,080 --> 00:09:00,455 Trying to grind them all out, they're not coming out. 253 00:09:00,541 --> 00:09:02,541 - Zero hop in paul's step. 254 00:09:02,584 --> 00:09:04,668 - Same with walter. 255 00:09:04,753 --> 00:09:07,504 - He still doesn't have a working billet. 256 00:09:07,589 --> 00:09:09,548 - But the weight of that clock's pretty severe, 257 00:09:09,633 --> 00:09:11,341 and I'm starting to freak out. 258 00:09:11,426 --> 00:09:13,009 Do I really have enough time? 259 00:09:13,095 --> 00:09:16,805 - Basically, I'm looking at two smiths that are in trouble: 260 00:09:16,890 --> 00:09:18,390 Walter and paul. 261 00:09:18,475 --> 00:09:20,850 This is a smith who's gone into his head. 262 00:09:20,936 --> 00:09:23,520 - The minutes are ticking down. 263 00:09:23,605 --> 00:09:26,565 I know this is taking more time than it should. 264 00:09:26,650 --> 00:09:28,650 - I'm starting to freak out. 265 00:09:28,735 --> 00:09:30,151 This isn't good. 266 00:09:30,237 --> 00:09:31,403 I don't know if I'm gonna make it. 267 00:09:31,488 --> 00:09:33,697 I don't know if I'm gonna make it. 268 00:09:33,782 --> 00:09:38,910 [dramatic music] 269 00:09:38,954 --> 00:09:40,870 - walter seems to be the only one 270 00:09:40,956 --> 00:09:42,247 that doesn't have one working billet now. 271 00:09:42,332 --> 00:09:45,667 - I get the third bar made, 272 00:09:45,752 --> 00:09:49,170 and I need to get these three bars forge welded together. 273 00:09:49,256 --> 00:09:51,715 At this point, I have zero room for error. 274 00:09:51,758 --> 00:09:52,966 - Walter's way behind. 275 00:09:53,051 --> 00:09:54,593 You've gotta start shaping a knife. 276 00:09:54,636 --> 00:09:55,760 - Yeah. 277 00:09:55,804 --> 00:09:58,388 - I finally finish grinding. 278 00:09:58,432 --> 00:10:00,515 I think my welds look solid. 279 00:10:00,601 --> 00:10:02,934 - Looks like paul's in the press now with his billet. 280 00:10:02,978 --> 00:10:05,645 He's starting to form what looks like a tang. 281 00:10:05,731 --> 00:10:09,149 - Now I have to try and hurry up and forge out the blade 282 00:10:09,234 --> 00:10:11,610 because I've lost time grinding. 283 00:10:11,653 --> 00:10:13,695 ♪ ♪ 284 00:10:13,780 --> 00:10:15,905 - I don't think it's gonna come down to the wire 285 00:10:15,949 --> 00:10:17,824 unless something unforeseen happens. 286 00:10:17,909 --> 00:10:19,326 Right now I'm finishing up, 287 00:10:19,411 --> 00:10:21,119 trying to get my proportions right, 288 00:10:21,163 --> 00:10:23,913 and then it's just grind, grind, grind 289 00:10:23,999 --> 00:10:25,957 until I feel like I'm ready to quench. 290 00:10:26,001 --> 00:10:27,417 ♪ ♪ 291 00:10:27,461 --> 00:10:30,629 - so we've got everybody with a pretty well shaped blade. 292 00:10:30,714 --> 00:10:32,922 - I'm getting ready for the quench, 293 00:10:33,008 --> 00:10:34,799 and I'm going to heat treat this 294 00:10:34,843 --> 00:10:36,676 with a little trick I brought from home, 295 00:10:36,762 --> 00:10:37,844 which is table salt. 296 00:10:37,929 --> 00:10:39,387 Table salt will melt 297 00:10:39,473 --> 00:10:41,973 at around 1,474 degrees. 298 00:10:42,017 --> 00:10:43,808 So I use the table salt to tell me 299 00:10:43,894 --> 00:10:45,352 when I'm up at critical temperature. 300 00:10:45,437 --> 00:10:47,228 Salt just makes everything better anyway. 301 00:10:47,314 --> 00:10:49,189 [rock music] 302 00:10:49,274 --> 00:10:51,191 - bryan just quenched. 303 00:10:51,276 --> 00:10:53,151 We'll see if bryan likes that hardening. 304 00:10:54,988 --> 00:10:56,988 ♪ ♪ 305 00:10:57,032 --> 00:10:58,573 - it's crazy how fast things can turn. 306 00:10:58,659 --> 00:11:00,784 I thought was paul was gassed and gonna be out of it, 307 00:11:00,869 --> 00:11:02,327 and walter didn't even have a billet, 308 00:11:02,371 --> 00:11:04,079 and now, it seems like 309 00:11:04,164 --> 00:11:06,331 they're both really turning the table. 310 00:11:06,375 --> 00:11:08,583 - I didn't quite get to everything I wanted, 311 00:11:08,669 --> 00:11:11,252 but I'm happy with the knife I finished for this round. 312 00:11:11,338 --> 00:11:15,215 ♪ ♪ 313 00:11:15,300 --> 00:11:16,549 - paul went in. 314 00:11:16,635 --> 00:11:18,343 - This is the right time to be quenching. 315 00:11:18,428 --> 00:11:20,095 I like it. 316 00:11:20,180 --> 00:11:21,930 - I feel good. 317 00:11:22,015 --> 00:11:23,682 - Right now, the clock is ticking down, 318 00:11:23,767 --> 00:11:25,642 and I stick the blade into the forge, 319 00:11:25,727 --> 00:11:28,603 just try and please, god, get hot enough. 320 00:11:28,689 --> 00:11:31,272 - Going for a quench. - Yeah. 321 00:11:31,358 --> 00:11:33,149 ♪ ♪ 322 00:11:33,235 --> 00:11:35,735 - walter is shaking his head yes. 323 00:11:35,821 --> 00:11:38,405 - She's singing like a canary with the file. 324 00:11:38,490 --> 00:11:39,823 It sounds good to me. 325 00:11:39,866 --> 00:11:42,701 - I have just over ten minutes. 326 00:11:42,744 --> 00:11:44,577 I'm grinding my raker into the blade, 327 00:11:44,663 --> 00:11:46,996 and something unforeseen has happened. 328 00:11:47,040 --> 00:11:49,708 I notice there's a weld flaw 329 00:11:49,751 --> 00:11:52,544 at the worst possible time. 330 00:11:52,587 --> 00:11:54,796 - Oh, no. - What's happening? 331 00:11:54,881 --> 00:11:56,923 - Are you guys seeing what I'm seeing on evan's blade? 332 00:11:57,008 --> 00:11:58,508 - Can I get past it? 333 00:11:58,552 --> 00:12:00,927 Is it just shallow? 334 00:12:01,012 --> 00:12:02,345 And the more I grind, 335 00:12:02,431 --> 00:12:04,222 the more I realize this isn't going away. 336 00:12:04,266 --> 00:12:06,766 - Aw, man, evan is back to the flux now. 337 00:12:06,852 --> 00:12:08,893 - Aw, that's not a good sign. 338 00:12:08,937 --> 00:12:10,061 Is this a hail mary? 339 00:12:10,147 --> 00:12:12,021 - It's a hail mary. 340 00:12:12,107 --> 00:12:13,857 - It's time to go back to reforge weld 341 00:12:13,942 --> 00:12:16,526 because if this doesn't get fixed, 342 00:12:16,611 --> 00:12:17,861 I'm going home. 343 00:12:17,946 --> 00:12:20,780 - We've got paul, walter, and bryan all quenched. 344 00:12:20,866 --> 00:12:23,575 Evan's the only one lagging behind them. 345 00:12:23,618 --> 00:12:25,034 - He's running out of time. 346 00:12:25,120 --> 00:12:26,453 - Get it? 347 00:12:26,538 --> 00:12:28,872 I think so. 348 00:12:28,915 --> 00:12:31,541 I get forged back together. 349 00:12:31,626 --> 00:12:34,252 I don't see any obvious problems with it. 350 00:12:34,296 --> 00:12:36,212 ♪ ♪ 351 00:12:36,256 --> 00:12:37,547 - quench it! It's hot enough. 352 00:12:37,591 --> 00:12:38,757 That's hot enough there. 353 00:12:38,842 --> 00:12:40,550 - Oh, boy. Oh, boy. 354 00:12:40,594 --> 00:12:41,926 - And at this point, 355 00:12:41,970 --> 00:12:43,928 it's either gonna be or it's not. 356 00:12:44,014 --> 00:12:46,556 - Five, four, three, 357 00:12:46,641 --> 00:12:48,975 two, one! 358 00:12:49,060 --> 00:12:50,727 Bladesmiths, turn off your machines! 359 00:12:50,812 --> 00:12:53,438 Put down your work! This round is over! 360 00:12:53,482 --> 00:12:56,149 ♪ ♪ 361 00:12:56,234 --> 00:12:58,943 - let me tell you something... [sighs] 362 00:12:58,987 --> 00:13:01,571 I had to dig down deep to pull that one off, 363 00:13:01,656 --> 00:13:03,406 but she's hard, 364 00:13:03,450 --> 00:13:06,951 and I'm happy I'm turning in a blade that meets parameters. 365 00:13:06,995 --> 00:13:08,369 - All right, guys, 366 00:13:08,455 --> 00:13:09,913 it's now time to see what the judges think of your work. 367 00:13:09,998 --> 00:13:10,997 Bryan, you're up first. 368 00:13:11,082 --> 00:13:13,082 Please present your weapon. 369 00:13:13,168 --> 00:13:15,293 [dramatic music] 370 00:13:15,378 --> 00:13:17,045 - all right, bryan, let's talk about your blade here. 371 00:13:17,130 --> 00:13:20,173 I like the profile that you have on this blade, 372 00:13:20,258 --> 00:13:22,467 and everything is solid, 373 00:13:22,511 --> 00:13:24,302 but there's a lot of metal that you have here. 374 00:13:24,346 --> 00:13:25,762 If you make forward, 375 00:13:25,847 --> 00:13:27,847 you'll have to lighten this blade a lot. 376 00:13:27,933 --> 00:13:30,391 Good job. - Thank you. 377 00:13:30,477 --> 00:13:31,810 - All right, evan, you're up next. 378 00:13:31,853 --> 00:13:33,645 Please present your weapon. 379 00:13:33,688 --> 00:13:35,480 ♪ ♪ 380 00:13:35,524 --> 00:13:39,108 - evan, stylistically, I like where you're going with this, 381 00:13:39,194 --> 00:13:41,027 but the issue is, is that 382 00:13:41,112 --> 00:13:44,447 big delamination that runs along the edge of this blade, 383 00:13:44,533 --> 00:13:46,074 and it looks fairly deep. 384 00:13:46,159 --> 00:13:48,368 Then there are numerous more visual ones, 385 00:13:48,453 --> 00:13:50,912 and I have no idea how deep those go. 386 00:13:50,997 --> 00:13:54,040 There are things that could happen 387 00:13:54,125 --> 00:13:55,166 to fix these problems, 388 00:13:55,252 --> 00:13:58,711 but they are significant. 389 00:13:58,797 --> 00:14:02,173 - All right, walter, you ready? Please present your work. 390 00:14:02,217 --> 00:14:03,466 ♪ ♪ 391 00:14:03,510 --> 00:14:04,717 - all right, walter, 392 00:14:04,803 --> 00:14:07,011 there's still a lot of meat to this blade. 393 00:14:07,097 --> 00:14:08,555 It's gonna take a lot of grinding, 394 00:14:08,640 --> 00:14:11,474 and I do see on the edge 395 00:14:11,560 --> 00:14:13,017 just whispers of lines 396 00:14:13,103 --> 00:14:15,061 that are between some of the cables. 397 00:14:15,146 --> 00:14:16,354 Those have to be gone. 398 00:14:16,398 --> 00:14:18,731 Even the tiniest little crack across that edge 399 00:14:18,817 --> 00:14:20,441 can be a stress riser 400 00:14:20,527 --> 00:14:22,443 and initiate a crack that goes all the way through your blade. 401 00:14:22,529 --> 00:14:23,945 But nice job. 402 00:14:24,030 --> 00:14:25,697 - Thank you, sir. 403 00:14:25,782 --> 00:14:28,616 - All right, paul, please present your weapon. 404 00:14:28,702 --> 00:14:29,951 ♪ ♪ 405 00:14:30,036 --> 00:14:31,619 - well, paul, 406 00:14:31,705 --> 00:14:34,080 you are by far the most meticulous smith out there. 407 00:14:34,165 --> 00:14:37,417 You paid a lot of attention to grinding your forge welds 408 00:14:37,502 --> 00:14:38,877 after they were done. 409 00:14:38,920 --> 00:14:41,129 I was nervous that you were spending too much time, 410 00:14:41,214 --> 00:14:44,549 and it does seem like you had to rush at the end. 411 00:14:44,634 --> 00:14:46,050 I would address the handle most, 412 00:14:46,136 --> 00:14:47,260 make sure that gets to be 413 00:14:47,345 --> 00:14:49,095 a comfortable well-proportioned handle, 414 00:14:49,180 --> 00:14:51,222 maybe doesn't have so much hanging off the back. 415 00:14:51,308 --> 00:14:54,642 So it's just aesthetics from here. 416 00:14:54,728 --> 00:14:55,727 ♪ ♪ 417 00:14:55,812 --> 00:14:57,270 - you all did great work on your weapons, 418 00:14:57,355 --> 00:14:59,898 but unfortunately, somebody does have to go home today. 419 00:14:59,983 --> 00:15:02,150 The bladesmith leaving the forge is... 420 00:15:02,235 --> 00:15:05,320 ♪ ♪ 421 00:15:05,405 --> 00:15:08,031 evan. 422 00:15:08,116 --> 00:15:10,074 - Evan, you did a lot of really good work out there, 423 00:15:10,118 --> 00:15:12,744 and you blade that was developing a really nice shape, 424 00:15:12,787 --> 00:15:15,079 but in the end, with all those delaminations, 425 00:15:15,165 --> 00:15:17,457 those are structural issues to the blade 426 00:15:17,542 --> 00:15:19,083 that none of the other competitors have. 427 00:15:19,127 --> 00:15:20,418 ♪ ♪ 428 00:15:20,462 --> 00:15:22,587 - evan, it's time for you to surrender your work 429 00:15:22,672 --> 00:15:23,838 and please leave the forge. 430 00:15:23,924 --> 00:15:25,381 ♪ ♪ 431 00:15:25,467 --> 00:15:26,883 - little sad. 432 00:15:26,968 --> 00:15:28,885 I didn't come here to lose. I came here to win. 433 00:15:28,970 --> 00:15:30,261 I'm not gonna let this beat me. 434 00:15:30,347 --> 00:15:32,263 I'm not gonna let this define me. 435 00:15:32,307 --> 00:15:34,432 Gonna go home, kiss my wife, 436 00:15:34,476 --> 00:15:36,184 drink a beer, get back to work. 437 00:15:36,269 --> 00:15:38,061 ♪ ♪ 438 00:15:38,146 --> 00:15:40,229 - all right, guys, you can take a breath. 439 00:15:40,315 --> 00:15:42,231 You're making it into round two of the competition. 440 00:15:42,317 --> 00:15:44,275 We're gonna ask you guys to add handles to your blades, 441 00:15:44,319 --> 00:15:46,152 making them fully functioning weapons. 442 00:15:46,237 --> 00:15:47,445 You'll see on your work stations, 443 00:15:47,489 --> 00:15:48,905 you each have two spools of wire, 444 00:15:48,949 --> 00:15:51,074 one tin and one brass. 445 00:15:51,159 --> 00:15:52,283 You'll need to twist those 446 00:15:52,327 --> 00:15:53,993 and incorporate them into your handles. 447 00:15:54,079 --> 00:15:55,495 At the end of round two, 448 00:15:55,580 --> 00:15:57,372 we're gonna test your blades for strength and durability 449 00:15:57,457 --> 00:15:59,666 in the animal horn chop 450 00:15:59,751 --> 00:16:01,459 and for edge retention and edge sharpness 451 00:16:01,544 --> 00:16:03,294 in the water tube slice. 452 00:16:03,380 --> 00:16:04,879 Keep your eyes on the clock. 453 00:16:04,965 --> 00:16:06,714 So you only have two hours for this round of the competition, 454 00:16:06,800 --> 00:16:09,008 and that time starts now. 455 00:16:09,094 --> 00:16:10,343 [rock music] 456 00:16:10,428 --> 00:16:13,471 - all three bladesmiths have a lot of grinding. 457 00:16:13,515 --> 00:16:15,640 - Oh, yeah. 458 00:16:15,725 --> 00:16:17,558 - My first objective in this round 459 00:16:17,644 --> 00:16:19,727 is to get all that material ground off 460 00:16:19,813 --> 00:16:21,145 because they told me it was too heavy. 461 00:16:21,231 --> 00:16:23,314 If I don't get moving fast enough, 462 00:16:23,358 --> 00:16:25,984 I'm not gonna be able to use up these two hours as I need to, 463 00:16:26,069 --> 00:16:27,151 and I'm not gonna have enough time 464 00:16:27,237 --> 00:16:28,987 to get everything I need done. 465 00:16:29,030 --> 00:16:31,572 ♪ ♪ 466 00:16:31,658 --> 00:16:32,657 - the first thing I do, 467 00:16:32,701 --> 00:16:34,200 I go over the handle material 468 00:16:34,285 --> 00:16:36,452 and try to find a big block 469 00:16:36,538 --> 00:16:40,164 that I know will fit the width of the handle that I forged. 470 00:16:40,250 --> 00:16:43,084 I tried to forge out the handle with enough room 471 00:16:43,169 --> 00:16:45,837 for me to shape it to fit my hand exactly. 472 00:16:45,880 --> 00:16:47,630 In the first round, I didn't get enough time to grind it 473 00:16:47,716 --> 00:16:49,007 completely to my hand. 474 00:16:49,050 --> 00:16:50,258 - Ben, it looks like paul's taking your advice 475 00:16:50,343 --> 00:16:51,467 on the handle. 476 00:16:51,511 --> 00:16:53,678 He's working on making it fit better. 477 00:16:53,722 --> 00:16:57,515 ♪ ♪ 478 00:16:57,600 --> 00:16:59,308 - my main concern 479 00:16:59,394 --> 00:17:01,644 is getting a majority of the meat off of this blade. 480 00:17:01,730 --> 00:17:04,147 Then I wanna make sure that there's not gonna be 481 00:17:04,232 --> 00:17:06,107 any major inclusions. 482 00:17:06,192 --> 00:17:08,860 - But I think that walter has a lot of grinding to do. 483 00:17:08,945 --> 00:17:10,361 He's gotta get down 484 00:17:10,405 --> 00:17:12,655 through all of those welds on the sides 485 00:17:12,741 --> 00:17:14,490 and see where things are. 486 00:17:14,534 --> 00:17:16,075 - A lot of those inclusions 487 00:17:16,161 --> 00:17:17,785 that I had seen on the surface, 488 00:17:17,871 --> 00:17:19,495 they're all fading away. 489 00:17:19,539 --> 00:17:21,581 I'm feeling pretty good. 490 00:17:21,666 --> 00:17:24,375 - Bladesmiths, you guys have one hour remaining. 491 00:17:24,419 --> 00:17:25,585 ♪ ♪ 492 00:17:25,670 --> 00:17:27,128 - I spent about an hour at the grinder, 493 00:17:27,213 --> 00:17:29,630 and I'm realizing that it's time to move on to my handle. 494 00:17:29,716 --> 00:17:33,342 My plan is to put these two pieces of wood together, 495 00:17:33,428 --> 00:17:35,261 super glue them just a little bit 496 00:17:35,346 --> 00:17:37,597 so that I can get a hole through both slabs of wood 497 00:17:37,682 --> 00:17:39,599 at the same time and keep everything lined up. 498 00:17:39,684 --> 00:17:42,101 - Look how tiny those scales are. 499 00:17:42,187 --> 00:17:44,228 - I got my two holes drilled. 500 00:17:44,314 --> 00:17:47,273 Now I need to take them apart. 501 00:17:47,358 --> 00:17:49,067 Come on now. 502 00:17:49,152 --> 00:17:52,028 I may have used too much glue. 503 00:17:52,947 --> 00:17:55,281 I'm worried about spending too much time on this. 504 00:17:55,366 --> 00:17:57,450 I've got to move on to the next step. 505 00:17:57,535 --> 00:18:00,203 I don't have time to go and start a whole other handle, 506 00:18:00,246 --> 00:18:03,581 so I decide to go over to the band saw and cut them again. 507 00:18:03,625 --> 00:18:05,083 - He already cut them apart 508 00:18:05,126 --> 00:18:07,085 just to glue them together and cut them back apart. 509 00:18:07,128 --> 00:18:09,295 Now he's back on the grinder going down even further 510 00:18:09,380 --> 00:18:10,588 taking that glue off, 511 00:18:10,673 --> 00:18:11,756 but you were saying 512 00:18:11,841 --> 00:18:13,091 they looked pretty slim as they were. 513 00:18:13,134 --> 00:18:14,509 - They look small in every dimension. 514 00:18:14,594 --> 00:18:16,344 - Yeah. 515 00:18:16,429 --> 00:18:17,804 ♪ ♪ 516 00:18:17,889 --> 00:18:19,263 - my handle's feeling good. 517 00:18:19,307 --> 00:18:22,558 Now I'm going to focus on twisting up the wire. 518 00:18:22,644 --> 00:18:24,602 - The easiest way to get a wire attached 519 00:18:24,646 --> 00:18:26,771 is to drill a hole where you're starting, 520 00:18:26,815 --> 00:18:28,564 cut a channel for it to sit in, 521 00:18:28,650 --> 00:18:30,441 wrap it, drill a hole, 522 00:18:30,527 --> 00:18:32,068 slide it all way through the handle material 523 00:18:32,112 --> 00:18:33,611 and glue it here going over. 524 00:18:33,655 --> 00:18:35,113 Paul's kinda gone down that road 525 00:18:35,156 --> 00:18:38,449 that I was hoping he'd go down. 526 00:18:38,493 --> 00:18:40,284 ♪ ♪ 527 00:18:40,328 --> 00:18:41,786 - my blade's looking good. 528 00:18:41,871 --> 00:18:44,247 I start setting myself up to make the knife scales. 529 00:18:44,332 --> 00:18:47,125 - Is walter cutting the shape out right now? 530 00:18:47,168 --> 00:18:48,251 Bad move. 531 00:18:48,294 --> 00:18:49,627 - To me, it's a waste, 532 00:18:49,671 --> 00:18:51,087 'cause he's gonna have to get up to that grinder 533 00:18:51,131 --> 00:18:53,840 and reshape those once they're on anyway. 534 00:18:53,925 --> 00:18:55,299 - So you would wanted to see him 535 00:18:55,343 --> 00:18:57,176 glue them on the handle itself? 536 00:18:57,262 --> 00:18:58,761 - If you're gonna use that technique... 537 00:18:58,847 --> 00:19:01,556 - That kind of tack glue. 538 00:19:01,641 --> 00:19:02,807 - Ah! 539 00:19:02,851 --> 00:19:05,143 I just screwed up big time. 540 00:19:05,186 --> 00:19:06,978 I ended up grinding the radius 541 00:19:07,063 --> 00:19:08,729 on the inside of the handle scale. 542 00:19:08,815 --> 00:19:10,940 The radius is the curves 543 00:19:10,984 --> 00:19:12,525 on the handle of your knife. 544 00:19:12,610 --> 00:19:14,694 - Uh-oh. Walter does not look happy. 545 00:19:14,779 --> 00:19:15,987 - I just made 546 00:19:16,072 --> 00:19:18,197 probably the simplest mistake you could make. 547 00:19:18,283 --> 00:19:20,199 - Walter cut his scales to shape, 548 00:19:20,285 --> 00:19:21,576 contoured one side correctly, 549 00:19:21,661 --> 00:19:24,287 then contoured the wrong side of the other scale. 550 00:19:24,372 --> 00:19:26,497 Now he has two right side scales. 551 00:19:26,541 --> 00:19:27,957 He's gonna have to redo it. 552 00:19:28,042 --> 00:19:29,375 - So this is a classic tale 553 00:19:29,460 --> 00:19:31,419 of you should've put it on the blade before grinding. 554 00:19:31,504 --> 00:19:32,670 - Yep. 555 00:19:32,714 --> 00:19:35,715 - I can't flip flop them. I have one done. 556 00:19:35,800 --> 00:19:38,092 This is gonna me some time, but I have to do it over. 557 00:19:38,178 --> 00:19:39,594 [sighs] 558 00:19:39,679 --> 00:19:43,139 - two seconds of grinding just set him back 30 minutes. 559 00:19:45,185 --> 00:19:48,102 [dramatic music] 560 00:19:48,188 --> 00:19:49,395 - ah! 561 00:19:49,480 --> 00:19:51,606 I just screwed up big time. 562 00:19:51,691 --> 00:19:54,525 - Uh-oh. Walter does not look happy. 563 00:19:54,569 --> 00:19:56,485 - I ended up grinding the radius 564 00:19:56,529 --> 00:19:58,446 on the inside of the handle scale. 565 00:19:58,531 --> 00:20:00,573 I--son of a... 566 00:20:00,658 --> 00:20:02,241 I have to do it over. 567 00:20:02,327 --> 00:20:03,409 - If all the three knives test out equally, 568 00:20:03,494 --> 00:20:05,119 the handle is quite often something 569 00:20:05,205 --> 00:20:07,830 that is pushed to the fore as a reason for elimination. 570 00:20:07,916 --> 00:20:09,498 - I just gotta relax, 571 00:20:09,584 --> 00:20:11,375 accept what happened, 572 00:20:11,461 --> 00:20:14,295 and keep moving on. 573 00:20:14,380 --> 00:20:15,713 [rock music] 574 00:20:15,798 --> 00:20:17,340 - I've done wire inlay before 575 00:20:17,383 --> 00:20:20,843 but not quite under this sort of an extreme circumstance. 576 00:20:20,887 --> 00:20:23,012 - Guys, you got 20 minutes remaining! 577 00:20:23,097 --> 00:20:24,555 Coming down to the "wire." 578 00:20:24,599 --> 00:20:28,184 [laughter] whoo! 579 00:20:28,269 --> 00:20:29,644 - Bryan's using the dremel 580 00:20:29,729 --> 00:20:32,063 to start probably putting the grooves for the inlay. 581 00:20:32,106 --> 00:20:33,356 - Yeah. 582 00:20:33,441 --> 00:20:36,234 - On those amazingly small handle scales. 583 00:20:36,277 --> 00:20:38,569 - I plan using four pieces of twisted wire 584 00:20:38,655 --> 00:20:40,571 and laying them at opposing angles, 585 00:20:40,657 --> 00:20:42,907 like that. 586 00:20:42,992 --> 00:20:46,661 - I think it's time to work on the blade edge. 587 00:20:46,746 --> 00:20:48,579 ♪ ♪ 588 00:20:48,623 --> 00:20:50,456 when I rock the blade back and forth, 589 00:20:50,541 --> 00:20:53,209 it's to create the convex edge, 590 00:20:53,294 --> 00:20:54,502 or an apple seed edge, 591 00:20:54,587 --> 00:20:57,255 where it brings the edge in so it's sharp, 592 00:20:57,298 --> 00:20:58,839 but it leaves a little bit of extra meat, 593 00:20:58,925 --> 00:21:00,967 so the blade edge should be stronger. 594 00:21:01,052 --> 00:21:02,969 - The thing about an animal horn chop 595 00:21:03,054 --> 00:21:06,389 is that horn allows the blade to dig in quite a bit, 596 00:21:06,432 --> 00:21:08,724 and if that edge is too fine, 597 00:21:08,768 --> 00:21:10,810 it'll actually get stuck in the horn, 598 00:21:10,895 --> 00:21:12,270 and if the blade rolls at all, 599 00:21:12,355 --> 00:21:14,063 it'll just snap its section out. 600 00:21:14,148 --> 00:21:16,732 - My blade isn't as pretty as I wanted it to be, 601 00:21:16,818 --> 00:21:19,110 but I'm just hoping that my edge holds up to the horn test. 602 00:21:19,153 --> 00:21:22,238 ♪ ♪ 603 00:21:22,323 --> 00:21:23,864 - I've not done any kind 604 00:21:23,950 --> 00:21:26,575 of twisted or grated wire like this on a handle before, 605 00:21:26,619 --> 00:21:30,246 but I need to make it happen fast. 606 00:21:30,290 --> 00:21:32,248 My plan of attack is to run 607 00:21:32,292 --> 00:21:34,417 two strips of the wire 608 00:21:34,460 --> 00:21:35,584 kind of on an angle, 609 00:21:35,670 --> 00:21:37,128 inlaid into the handle. 610 00:21:37,171 --> 00:21:39,171 - He's doing, like, a 3/4 wrap. 611 00:21:39,257 --> 00:21:41,382 So when the scales go together, 612 00:21:41,467 --> 00:21:44,552 the ends of the wire will be between the tang 613 00:21:44,637 --> 00:21:45,803 and the scale. 614 00:21:45,888 --> 00:21:47,596 - I'm running out of time. 615 00:21:47,682 --> 00:21:49,140 I'm going into panic mode. 616 00:21:49,183 --> 00:21:50,850 So I glue the handle scales on, 617 00:21:50,935 --> 00:21:52,852 and I'm not gonna sit around 618 00:21:52,937 --> 00:21:54,353 and wait for everything to dry. 619 00:21:54,439 --> 00:21:56,439 I'm gonna start putting the finished edge on this knife. 620 00:21:56,524 --> 00:21:58,649 [dramatic music] 621 00:21:58,735 --> 00:22:01,986 - five, four, three, 622 00:22:02,030 --> 00:22:03,529 two, one. 623 00:22:03,614 --> 00:22:05,656 Put down your tools. Put your blades down. 624 00:22:05,742 --> 00:22:07,116 This round is over. 625 00:22:07,201 --> 00:22:10,578 - Good job, man. - Hell yeah, brother. 626 00:22:10,663 --> 00:22:11,662 ♪ ♪ 627 00:22:11,748 --> 00:22:13,331 - I'm feeling good about my knife. 628 00:22:13,374 --> 00:22:14,832 I'm a little bit concerned that the edge 629 00:22:14,876 --> 00:22:16,375 might not be strong enough 630 00:22:16,461 --> 00:22:19,503 'cause I think I did grind a little bit too much away, 631 00:22:19,547 --> 00:22:21,005 but it might be able to hold up to the horn. 632 00:22:21,049 --> 00:22:24,759 ♪ ♪ 633 00:22:24,844 --> 00:22:27,178 - bladesmiths, welcome to the strength test: 634 00:22:27,263 --> 00:22:28,929 The animal horn chop. 635 00:22:29,015 --> 00:22:30,681 ♪ ♪ 636 00:22:30,767 --> 00:22:32,058 to test the strength and durability of your edge 637 00:22:32,143 --> 00:22:33,684 as well as your overall construction of your knives, 638 00:22:33,770 --> 00:22:35,686 I'll be chopping into these animal horns. 639 00:22:35,730 --> 00:22:36,979 Remember, this test is all about 640 00:22:37,065 --> 00:22:38,230 what those horns do to your knives, 641 00:22:38,316 --> 00:22:39,648 not what your knives do to the horns. 642 00:22:39,734 --> 00:22:41,192 Bryan, you're up first. You ready? 643 00:22:41,235 --> 00:22:42,193 - Yes, sir. 644 00:22:42,278 --> 00:22:44,362 - All right. 645 00:22:44,405 --> 00:22:46,864 - It's antler chop, and that's a pretty rugged thing 646 00:22:46,908 --> 00:22:48,366 to be putting the blade through. 647 00:22:48,409 --> 00:22:50,368 I do not normally check my knives with antler. 648 00:22:50,411 --> 00:22:52,119 I normally check them on my fingernail. 649 00:22:52,205 --> 00:22:59,001 ♪ ♪ 650 00:23:02,298 --> 00:23:03,714 [sighs] 651 00:23:06,135 --> 00:23:07,259 - well, bryan, 652 00:23:07,345 --> 00:23:09,178 you took a lot of the weight out of this blade, 653 00:23:09,263 --> 00:23:10,596 and thank you very much for that. 654 00:23:10,681 --> 00:23:12,181 Your edge held up great. 655 00:23:12,225 --> 00:23:14,517 The handle is a bit small right here. 656 00:23:14,602 --> 00:23:16,727 I am not getting a good grip on my pointer finger 657 00:23:16,813 --> 00:23:18,729 where I really get a lot of control, 658 00:23:18,773 --> 00:23:20,856 but in all, it's a strong blade, 659 00:23:20,942 --> 00:23:22,066 it's a good looking blade, 660 00:23:22,151 --> 00:23:24,026 just a little bit of issue on the handle here. 661 00:23:24,070 --> 00:23:25,778 - Thank you very much. 662 00:23:25,863 --> 00:23:28,072 - All right, walter, can you hear your heartbeat yet? 663 00:23:28,116 --> 00:23:31,826 - It's in my throat. - [laughing] 664 00:23:31,911 --> 00:23:33,244 ♪ ♪ 665 00:23:33,287 --> 00:23:34,286 - oh, boy. 666 00:23:34,372 --> 00:23:37,081 My heart is just a-jamming. 667 00:23:37,125 --> 00:23:38,916 I don't know what's about to happen. 668 00:23:39,001 --> 00:23:40,876 I don't know if my blade's about to blow apart 669 00:23:40,920 --> 00:23:42,169 into a million pieces. 670 00:23:42,255 --> 00:23:43,254 ♪ ♪ 671 00:23:43,339 --> 00:23:45,089 I'm pretty nervous about this test. 672 00:23:45,133 --> 00:23:52,096 ♪ ♪ 673 00:23:56,769 --> 00:23:59,478 - all right, walter, this is a... 674 00:23:59,564 --> 00:24:01,647 This is a cool knife. I like this thing. 675 00:24:01,732 --> 00:24:03,399 As for the edge, 676 00:24:03,484 --> 00:24:06,652 there is one deflection right there. 677 00:24:06,737 --> 00:24:08,237 It's a deflection of the edge, 678 00:24:08,322 --> 00:24:10,823 and also a delamination of one of the wires of the cable. 679 00:24:10,908 --> 00:24:12,074 So it's kinda popped out, 680 00:24:12,160 --> 00:24:14,160 and it's sharp if I run my finger this way, 681 00:24:14,245 --> 00:24:16,162 but the rest of your edge 682 00:24:16,247 --> 00:24:17,455 is still nice and sharp. 683 00:24:17,498 --> 00:24:19,790 All in all, nice job. - Thank you, sir. 684 00:24:19,876 --> 00:24:22,376 - All right, paul, you're up. You ready for this? 685 00:24:22,462 --> 00:24:23,544 - Eh. - Yeah. 686 00:24:23,629 --> 00:24:25,045 - All right, cool. 687 00:24:25,131 --> 00:24:26,297 ♪ ♪ 688 00:24:26,382 --> 00:24:27,840 - seeing the way ben hit those horns 689 00:24:27,925 --> 00:24:29,467 with bryan and walter's knives 690 00:24:29,510 --> 00:24:32,136 got me a little bit worried about how thin my edge is. 691 00:24:32,221 --> 00:24:34,763 I might've taken a little bit of strength 692 00:24:34,849 --> 00:24:36,640 out of the edge trying to sharpen it. 693 00:24:36,684 --> 00:24:38,559 I'm not sure if my edge will hold up. 694 00:24:38,644 --> 00:24:45,608 ♪ ♪ 695 00:24:49,530 --> 00:24:51,906 - all right, paul. This is a chopper, man. 696 00:24:51,991 --> 00:24:55,034 As it stands, there's a little edge deflection right here. 697 00:24:55,119 --> 00:24:57,661 You can feel it, you can hear it. 698 00:24:57,705 --> 00:24:59,455 Moving back to your handle here, 699 00:24:59,499 --> 00:25:02,041 the contouring you have on this handle 700 00:25:02,126 --> 00:25:05,002 is just a little too narrow in the front here 701 00:25:05,046 --> 00:25:06,337 and in the back here, 702 00:25:06,380 --> 00:25:08,839 but all in all, it's strong, and it did really well. 703 00:25:08,883 --> 00:25:10,424 - Thank you. 704 00:25:10,510 --> 00:25:11,842 ♪ ♪ 705 00:25:11,928 --> 00:25:14,845 - all right, bladesmiths, this is the water tube slice. 706 00:25:14,889 --> 00:25:16,263 ♪ ♪ 707 00:25:16,349 --> 00:25:18,057 to find out how sharp your edges are, 708 00:25:18,142 --> 00:25:20,559 I will take your knife, try to cut through these water tubes. 709 00:25:20,645 --> 00:25:22,019 Bryan, you're up first. You ready for this? 710 00:25:22,063 --> 00:25:24,104 - Absolutely. - Let's do this. 711 00:25:24,190 --> 00:25:25,272 ♪ ♪ 712 00:25:25,358 --> 00:25:26,690 - I'm very concerned at this point 713 00:25:26,776 --> 00:25:28,484 that because we're so even, 714 00:25:28,569 --> 00:25:30,027 it's gonna be left down to the details, 715 00:25:30,071 --> 00:25:31,570 so I'm really hoping that it cuts 716 00:25:31,614 --> 00:25:33,822 straight through the tubes and doesn't shatter any of them 717 00:25:33,866 --> 00:25:35,074 or push them around. 718 00:25:35,159 --> 00:25:36,951 I just do not want to get sent home. 719 00:25:37,036 --> 00:25:41,163 ♪ ♪ 720 00:25:41,249 --> 00:25:43,457 - I'm very concerned at this point. 721 00:25:43,543 --> 00:25:45,084 ♪ ♪ 722 00:25:45,169 --> 00:25:47,836 I'm really hoping it'll go through the water tubes. 723 00:25:47,922 --> 00:25:54,969 ♪ ♪ 724 00:25:56,222 --> 00:25:58,639 - splashed in here. - [laughs quietly] 725 00:25:58,724 --> 00:26:01,058 ♪ ♪ 726 00:26:01,102 --> 00:26:03,269 - all right, bryan, let's talk about your knife here. 727 00:26:03,354 --> 00:26:06,188 It is a light and fast blade, 728 00:26:06,274 --> 00:26:08,691 and it cut cleanly. 729 00:26:08,776 --> 00:26:11,569 That's one of the cleanest cuts we've had on water tubes. 730 00:26:11,612 --> 00:26:14,488 Overall, sir, it will cut. 731 00:26:14,574 --> 00:26:16,156 - Thank you. 732 00:26:16,242 --> 00:26:17,575 - Walter, your turn, sir. Ready? 733 00:26:17,618 --> 00:26:19,827 - Let's do this. - Let's do this. 734 00:26:19,912 --> 00:26:26,875 ♪ ♪ 735 00:26:35,553 --> 00:26:39,597 all right, walter, your edge is sharp. 736 00:26:39,682 --> 00:26:41,599 It's got a clean cut through the water tubes. 737 00:26:41,642 --> 00:26:43,434 What I like about this is, 738 00:26:43,519 --> 00:26:45,311 the balance is right to be able to control this blade. 739 00:26:45,396 --> 00:26:47,813 Overall, sir, it will cut. 740 00:26:47,898 --> 00:26:50,524 - Dream come true hearing you say that. 741 00:26:50,610 --> 00:26:52,860 - All right, paul, your turn. You ready? 742 00:26:52,945 --> 00:26:54,903 - I'm ready. - Let's do this. 743 00:26:54,989 --> 00:27:01,952 ♪ ♪ 744 00:27:10,129 --> 00:27:11,629 all right, paul, your edge here 745 00:27:11,714 --> 00:27:13,464 cut cleanly on these water tubes. 746 00:27:13,549 --> 00:27:15,633 There is some weight to this blade, 747 00:27:15,718 --> 00:27:16,925 but it will cut. 748 00:27:17,011 --> 00:27:19,136 - Thank you. 749 00:27:19,221 --> 00:27:22,181 - All right, guys, you all performed extremely well, 750 00:27:22,266 --> 00:27:25,225 and it came down to extremely minor details. 751 00:27:25,311 --> 00:27:27,019 Somebody's not gonna be moving forward 752 00:27:27,104 --> 00:27:28,646 into round three of the competition, 753 00:27:28,689 --> 00:27:32,024 and that bladesmith is... 754 00:27:32,109 --> 00:27:33,400 Paul. 755 00:27:33,486 --> 00:27:35,069 Ben abbott's gonna tell you why. 756 00:27:35,154 --> 00:27:36,654 - Well, paul, all of the blades out there 757 00:27:36,739 --> 00:27:39,365 had either a handle issue or a blade issue. 758 00:27:39,450 --> 00:27:41,867 Unfortunately, yours had both. 759 00:27:41,952 --> 00:27:43,744 - Paul, you clearly put out a lot of effort, 760 00:27:43,829 --> 00:27:45,245 but it's time you leave the forge floor. 761 00:27:45,331 --> 00:27:47,081 - Thanks, guys. I had a good time. 762 00:27:47,166 --> 00:27:48,374 Congrats, you guys. - Great work, man. 763 00:27:48,459 --> 00:27:49,917 - Good job, man. 764 00:27:50,002 --> 00:27:51,335 - I'm pretty disappointed I'm going home, 765 00:27:51,420 --> 00:27:54,213 but I'm gonna at it, keep making knives. 766 00:27:54,298 --> 00:27:55,756 I came to try and win. 767 00:27:55,841 --> 00:27:58,175 I didn't win, so I'm not particularly happy about it, 768 00:27:58,219 --> 00:28:00,594 but I had a fun time. 769 00:28:00,680 --> 00:28:01,762 ♪ ♪ 770 00:28:01,847 --> 00:28:03,514 - bryan, walter, congratulations. 771 00:28:03,557 --> 00:28:06,350 Both of you guys are moving forward into the next round. 772 00:28:06,394 --> 00:28:07,768 Round three of the competition, 773 00:28:07,853 --> 00:28:09,269 we're gonna be sending you guys back to your home forges 774 00:28:09,355 --> 00:28:11,438 to build an iconic weapon from history, 775 00:28:11,524 --> 00:28:12,940 and that weapon is... 776 00:28:13,025 --> 00:28:17,277 ♪ ♪ 777 00:28:17,363 --> 00:28:19,780 the sword of saladin. 778 00:28:19,865 --> 00:28:21,407 - [laughs] 779 00:28:21,492 --> 00:28:23,117 - this 12th century sword 780 00:28:23,202 --> 00:28:24,535 belonged to saladin, 781 00:28:24,620 --> 00:28:26,453 a powerful muslim leader, 782 00:28:26,539 --> 00:28:28,122 and the first sultan of egypt and syria. 783 00:28:28,207 --> 00:28:30,582 Believed to be forged from steel 784 00:28:30,668 --> 00:28:33,085 far superior than any other weapon of the time, 785 00:28:33,170 --> 00:28:35,629 the sword is rumored to be the sharpest in history. 786 00:28:35,715 --> 00:28:37,297 Featuring a thin edged geometry, 787 00:28:37,383 --> 00:28:38,882 the lightweight curved blade 788 00:28:38,968 --> 00:28:41,260 is designed to effortlessly deliver deep cuts 789 00:28:41,345 --> 00:28:42,553 and lethal chops. 790 00:28:42,596 --> 00:28:44,179 With the help of this deadly weapon, 791 00:28:44,265 --> 00:28:47,015 saladin founded a dynasty that ruled much of the middle east 792 00:28:47,101 --> 00:28:49,476 for the 12th and 13th centuries. 793 00:28:49,562 --> 00:28:51,061 The sword is a prominent feature 794 00:28:51,105 --> 00:28:52,855 of a statue memorializing saladin 795 00:28:52,898 --> 00:28:54,231 that stands in front 796 00:28:54,275 --> 00:28:56,942 of the ancient city of damascus in syria. 797 00:28:57,027 --> 00:28:59,403 - You guys need to follow these parameters. 798 00:28:59,447 --> 00:29:01,989 Your blade length as measured from tip to guard 799 00:29:02,074 --> 00:29:04,241 needs to be between 28 and 30 inches. 800 00:29:04,285 --> 00:29:05,909 The blade needs to be curved. 801 00:29:05,953 --> 00:29:08,954 You need to have a crossguard and a boot shaped handle. 802 00:29:09,039 --> 00:29:12,166 - I'm absolutely excited. 803 00:29:12,251 --> 00:29:13,459 It's a lot longer than what I normally build, 804 00:29:13,544 --> 00:29:15,627 but yeah, we can do this. 805 00:29:15,713 --> 00:29:18,130 - You guys will only have four days to complete this weapon, 806 00:29:18,215 --> 00:29:19,381 so we'll see you when you get back. 807 00:29:19,467 --> 00:29:22,050 Good luck. 808 00:29:22,094 --> 00:29:24,845 [rock music] 809 00:29:24,930 --> 00:29:26,847 - we're back here, baranowski knife & tool, 810 00:29:26,932 --> 00:29:28,432 in good old springfield, new york. 811 00:29:28,517 --> 00:29:29,725 I'm ready to get after it. 812 00:29:29,810 --> 00:29:31,268 You know, saladin's sword, 813 00:29:31,312 --> 00:29:32,770 a lot of history. 814 00:29:32,813 --> 00:29:35,898 You know, we're talking back to the great holy crusades. 815 00:29:35,983 --> 00:29:39,651 Day one, I really wanna get this blade forged 816 00:29:39,737 --> 00:29:41,945 and rough ground. 817 00:29:42,031 --> 00:29:44,823 My biggest concern is time management. 818 00:29:44,909 --> 00:29:47,993 When you're on a timed challenge like this, 819 00:29:48,078 --> 00:29:49,787 every minute is precious. 820 00:29:49,872 --> 00:29:51,246 Curve's going pretty well. 821 00:29:51,332 --> 00:29:52,706 I'm done with my forging. 822 00:29:52,792 --> 00:29:53,791 I head straight to the grinder 823 00:29:53,876 --> 00:29:55,042 and start cleaning this thing up, 824 00:29:55,127 --> 00:29:57,002 make it look right. 825 00:29:57,087 --> 00:29:59,421 All right, that's it for day one. 826 00:29:59,507 --> 00:30:01,340 ♪ ♪ 827 00:30:01,425 --> 00:30:02,966 - back at my home forge, 828 00:30:03,052 --> 00:30:04,551 I'm very excited to be in the third round. 829 00:30:04,637 --> 00:30:07,930 My plan is to get the blade cut out, 830 00:30:08,015 --> 00:30:09,473 get an arc bent into it, 831 00:30:09,558 --> 00:30:11,642 and get it ready for heat treat. 832 00:30:11,727 --> 00:30:13,560 Making a sword with a bend in it 833 00:30:13,646 --> 00:30:15,437 in such a steep arc like this 834 00:30:15,523 --> 00:30:17,689 is worrying me a little bit. 835 00:30:17,775 --> 00:30:19,149 I've not done a heat treat 836 00:30:19,193 --> 00:30:21,193 on something of this shape before. 837 00:30:21,278 --> 00:30:22,986 Close. 838 00:30:23,030 --> 00:30:24,696 So I'm a little worried about the heat treat. 839 00:30:24,782 --> 00:30:27,115 And away we go. 840 00:30:27,201 --> 00:30:32,246 ♪ ♪ 841 00:30:32,331 --> 00:30:34,081 oh, yeah. 842 00:30:34,166 --> 00:30:35,749 That's it. 843 00:30:35,835 --> 00:30:37,626 ♪ ♪ 844 00:30:37,711 --> 00:30:39,753 - day two, plan of attack: 845 00:30:39,839 --> 00:30:41,171 Start working on the guard, 846 00:30:41,215 --> 00:30:42,422 and before the end of the day, 847 00:30:42,508 --> 00:30:43,966 we're gonna get this knife quenched. 848 00:30:44,051 --> 00:30:45,843 This guard in particular 849 00:30:45,886 --> 00:30:49,096 is probably the most time I've ever really invested 850 00:30:49,181 --> 00:30:50,556 into a guard itself. 851 00:30:50,599 --> 00:30:52,891 I just don't want to make something kinda plain jane. 852 00:30:52,977 --> 00:30:53,892 It's getting there. 853 00:30:53,978 --> 00:30:55,978 Time to quench. 854 00:30:56,063 --> 00:31:02,693 ♪ ♪ 855 00:31:02,736 --> 00:31:05,320 that's the sound of success right there. 856 00:31:05,406 --> 00:31:06,780 ♪ ♪ 857 00:31:06,866 --> 00:31:08,782 - it's day three. Yesterday went well. 858 00:31:08,868 --> 00:31:11,410 I got the quillon on it. I like it. 859 00:31:11,495 --> 00:31:12,953 And I get the pommel built 860 00:31:13,038 --> 00:31:14,580 pretty much the shape that I want. 861 00:31:14,665 --> 00:31:16,707 My plan for day three is to get the handle 862 00:31:16,750 --> 00:31:17,916 at least roughed out. 863 00:31:18,002 --> 00:31:20,252 This is a emerald dyed box elder burl. 864 00:31:20,337 --> 00:31:21,378 I want it to look jeweled 865 00:31:21,463 --> 00:31:24,256 without actually being jeweled. 866 00:31:24,341 --> 00:31:26,592 So I got everything pretty well roughed in here. 867 00:31:26,677 --> 00:31:28,927 I'm just kind of pecking away at it going slowly. 868 00:31:29,013 --> 00:31:30,512 My blade is all together, 869 00:31:30,556 --> 00:31:32,639 and I'm very pleased to be where I am today. 870 00:31:32,725 --> 00:31:34,224 ♪ ♪ 871 00:31:34,268 --> 00:31:36,268 nobody is gonna be able to complain 872 00:31:36,353 --> 00:31:39,438 about that handle at all. 873 00:31:39,523 --> 00:31:41,815 [cows mooing] 874 00:31:41,901 --> 00:31:43,734 - day three. Feeling pretty good. 875 00:31:43,777 --> 00:31:46,111 Man, that's gonna be nice. [whistles] 876 00:31:46,196 --> 00:31:49,907 I'm using really, really pretty piece of amboyna burl. 877 00:31:49,950 --> 00:31:51,909 It's incredibly dense. 878 00:31:51,994 --> 00:31:54,912 One downside to it is because it's so dense, 879 00:31:54,997 --> 00:31:56,955 the grain can be kind of unpredictable. 880 00:31:57,041 --> 00:31:58,916 So I'm gonna take my time, 881 00:31:59,001 --> 00:32:00,292 I'm gonna do things a little bit slow. 882 00:32:00,377 --> 00:32:01,585 I wanna make sure 883 00:32:01,629 --> 00:32:04,421 that everything is lined up properly. 884 00:32:04,465 --> 00:32:07,424 Aw, man, that thing's really on there for some reason. 885 00:32:07,468 --> 00:32:10,385 [dramatic music] 886 00:32:10,471 --> 00:32:14,890 ♪ ♪ 887 00:32:16,518 --> 00:32:19,186 ♪ ♪ 888 00:32:19,271 --> 00:32:20,687 really? 889 00:32:20,773 --> 00:32:22,773 I'm gonna need--I'm seriously gonna need a minute, 890 00:32:22,816 --> 00:32:24,358 'cause I'm about to freak out. 891 00:32:24,443 --> 00:32:26,109 I ain't even lying right now. 892 00:32:26,195 --> 00:32:28,236 I can't believe I just did this. 893 00:32:28,322 --> 00:32:30,489 I got one freaking day left. 894 00:32:30,574 --> 00:32:35,869 [bleep] damn it. 895 00:32:35,955 --> 00:32:38,038 - Man, that thing's really on there for some reason. 896 00:32:38,123 --> 00:32:39,247 Ah, boy. 897 00:32:39,333 --> 00:32:41,124 I can't get that [bleep] handle off. 898 00:32:41,168 --> 00:32:44,086 [dramatic music] 899 00:32:44,171 --> 00:32:47,130 ♪ ♪ 900 00:32:48,634 --> 00:32:51,134 it was going good till I had to ruin it. 901 00:32:51,220 --> 00:32:52,803 My main concern right now: 902 00:32:52,846 --> 00:32:55,097 Is my new handle construction gonna be able to hold up? 903 00:32:55,140 --> 00:32:57,140 We're kind of down into the 11th hour, 904 00:32:57,226 --> 00:33:00,268 and I really hope I have enough time to finish this blade. 905 00:33:00,354 --> 00:33:02,437 I got a lot of work to do tomorrow. 906 00:33:02,481 --> 00:33:04,064 [rock music] 907 00:33:04,149 --> 00:33:05,607 - going into day four, 908 00:33:05,693 --> 00:33:07,150 what we have left to do today 909 00:33:07,194 --> 00:33:09,653 is fine details, little things 910 00:33:09,697 --> 00:33:11,780 that are gonna make it pop maybe more than my competitor. 911 00:33:11,865 --> 00:33:13,490 We'll get everything together. 912 00:33:13,575 --> 00:33:15,993 I'm gonna carve saladin's name 913 00:33:16,078 --> 00:33:18,704 into the spine of the blade back here in arabic 914 00:33:18,789 --> 00:33:21,248 just as kind of a last little minute flourish. 915 00:33:21,333 --> 00:33:22,666 I'm happy with the way it came out. 916 00:33:22,710 --> 00:33:24,209 End of day four. 917 00:33:24,294 --> 00:33:25,836 This has been a hell of a ride, 918 00:33:25,921 --> 00:33:28,672 but I hope that can bring me home the bacon. 919 00:33:28,716 --> 00:33:31,633 [dramatic music] 920 00:33:31,719 --> 00:33:33,135 ♪ ♪ 921 00:33:33,220 --> 00:33:34,970 - well, gentlemen, welcome back to the forge. 922 00:33:35,014 --> 00:33:38,098 You guys had four days to work on your saladin swords, 923 00:33:38,183 --> 00:33:40,767 and we absolutely cannot wait to hear about them. 924 00:33:40,853 --> 00:33:42,436 Bryan, tell us about your sword. 925 00:33:42,521 --> 00:33:45,856 - You have a blade of 80crv2, 926 00:33:45,941 --> 00:33:47,149 the quillon and the pommel 927 00:33:47,234 --> 00:33:49,276 are both fabricated mild steel, 928 00:33:49,361 --> 00:33:51,486 and the handle is emerald dyed 929 00:33:51,572 --> 00:33:54,448 and stabilized box elder burl. 930 00:33:54,533 --> 00:33:56,450 - Walter, how 'bout you? 931 00:33:56,535 --> 00:33:59,369 - My blade is made from 5160. 932 00:33:59,413 --> 00:34:00,829 The guard, long jays, 933 00:34:00,914 --> 00:34:03,415 and pommel is made from mild steel. 934 00:34:03,500 --> 00:34:05,292 My handle is a amboyna burl 935 00:34:05,377 --> 00:34:07,461 with ziricote in the center. 936 00:34:07,546 --> 00:34:09,129 - It seems like you guys both did a great job. 937 00:34:09,214 --> 00:34:11,715 They look absolutely terrifyingly sharp, 938 00:34:11,800 --> 00:34:13,884 but only one of you guys will be going home with the title 939 00:34:13,927 --> 00:34:15,552 and the check for $10,000. 940 00:34:15,637 --> 00:34:17,721 And really the only way for us to figure that out 941 00:34:17,806 --> 00:34:19,056 is by putting them through some tests. 942 00:34:19,099 --> 00:34:21,183 We've got a strength test, a sharpness test, 943 00:34:21,268 --> 00:34:22,851 and up first, the keal test. 944 00:34:22,936 --> 00:34:23,852 Doug. 945 00:34:23,937 --> 00:34:28,273 ♪ ♪ 946 00:34:28,358 --> 00:34:31,109 - bladesmiths, welcome to the keal test. 947 00:34:31,195 --> 00:34:33,737 To find out what kind of lethal damage your weapons will do, 948 00:34:33,822 --> 00:34:36,073 I will take your version of saladin's sword 949 00:34:36,158 --> 00:34:38,075 and deliver some lethal blows 950 00:34:38,160 --> 00:34:39,868 on this ram carcass. 951 00:34:39,953 --> 00:34:41,411 Bryan, you're up first. You ready for this? 952 00:34:41,497 --> 00:34:43,580 - No, but I guess you gotta do what you gotta do. 953 00:34:43,624 --> 00:34:44,998 - Absolutely. Let's do it. 954 00:34:45,084 --> 00:34:46,583 - To see that animal sitting there 955 00:34:46,668 --> 00:34:47,918 with the horns hanging out, 956 00:34:47,961 --> 00:34:50,629 uh, it's nerve-racking. 957 00:34:50,714 --> 00:34:53,340 It's pretty hard on a blade, 958 00:34:53,425 --> 00:34:55,717 so I'm not sure what's gonna happen. 959 00:34:55,803 --> 00:35:02,766 ♪ ♪ 960 00:35:12,569 --> 00:35:15,028 - all right, bryan, let's talk about your version 961 00:35:15,114 --> 00:35:16,655 of saladin's sword here. 962 00:35:16,740 --> 00:35:18,156 I noticed you have something inscribed in there. 963 00:35:18,242 --> 00:35:19,616 What is that? 964 00:35:19,701 --> 00:35:22,786 - That is "saladin" in arabic. - Very cool, very cool. 965 00:35:22,871 --> 00:35:26,248 Now, your edge-- you have a sharp edge. 966 00:35:26,333 --> 00:35:29,376 This is a very tough ram carcass. 967 00:35:29,461 --> 00:35:31,753 On the neck chops, it cut deeply, 968 00:35:31,839 --> 00:35:35,006 and of course on the body, it cut through in three slices. 969 00:35:35,092 --> 00:35:36,299 Overall, sir, 970 00:35:36,385 --> 00:35:39,761 your weapon will keal. 971 00:35:39,847 --> 00:35:41,096 - Thank you, sir. 972 00:35:41,140 --> 00:35:42,597 - All right, walter. Your turn, sir, you ready? 973 00:35:42,683 --> 00:35:44,307 - Let's make some ram chops. 974 00:35:44,393 --> 00:35:45,851 - All right. 975 00:35:45,936 --> 00:35:48,311 - Them bones in the ram, those are no joke. 976 00:35:48,397 --> 00:35:50,939 Their hides are as tough as leather. 977 00:35:51,024 --> 00:35:53,150 Their fur is abrasive like sandpaper. 978 00:35:53,235 --> 00:35:55,485 This is a legit test. 979 00:35:55,529 --> 00:35:58,113 I'm slightly freaking out on the inside right now. 980 00:35:58,198 --> 00:36:05,245 ♪ ♪ 981 00:36:09,877 --> 00:36:11,626 - that was nice. 982 00:36:11,712 --> 00:36:13,044 ♪ ♪ 983 00:36:13,130 --> 00:36:15,672 - all right, walter, first up, your edge. 984 00:36:15,757 --> 00:36:18,967 This is a wicked sharp grind. 985 00:36:19,052 --> 00:36:20,886 Actually, you know, it sings to me 986 00:36:20,971 --> 00:36:22,596 when I just touch it and pull it out. 987 00:36:22,681 --> 00:36:24,181 It is sharp. 988 00:36:24,224 --> 00:36:27,350 Cutting through hair, a thick spine, 989 00:36:27,394 --> 00:36:28,894 and into the meat. 990 00:36:28,979 --> 00:36:30,061 Overall, sir, 991 00:36:30,147 --> 00:36:32,189 your weapon will keal. 992 00:36:32,274 --> 00:36:33,648 - Thank you, sir. 993 00:36:33,734 --> 00:36:36,693 ♪ ♪ 994 00:36:36,778 --> 00:36:38,111 - all right, gentlemen, you know what time it is. 995 00:36:38,197 --> 00:36:39,529 It's time for the strength test. 996 00:36:39,573 --> 00:36:42,324 Now, saladin's army in 12th century 997 00:36:42,409 --> 00:36:44,743 would've faced off against men wearing chainmail, 998 00:36:44,828 --> 00:36:46,453 carrying shields, and probably a helmet. 999 00:36:46,538 --> 00:36:48,872 Now, to test your blade's construction, 1000 00:36:48,957 --> 00:36:50,332 overall durability, 1001 00:36:50,375 --> 00:36:52,667 I'll be hacking into our armored warriors here. 1002 00:36:52,753 --> 00:36:54,586 Bryan, you're up. 1003 00:36:54,671 --> 00:36:56,171 - Go ahead. 1004 00:36:56,256 --> 00:36:59,507 ♪ ♪ 1005 00:36:59,593 --> 00:37:01,426 chopping into chainmail, 1006 00:37:01,511 --> 00:37:03,303 metal helmets, and metal shields, 1007 00:37:03,388 --> 00:37:05,222 that never does any good for an edge. 1008 00:37:05,307 --> 00:37:07,390 I am rather nervous. 1009 00:37:07,476 --> 00:37:09,184 I'm not sure what's gonna happen. 1010 00:37:09,269 --> 00:37:13,396 ♪ ♪ 1011 00:37:13,440 --> 00:37:15,190 - I am rather nervous. 1012 00:37:15,275 --> 00:37:16,983 Chopping into chainmail, 1013 00:37:17,069 --> 00:37:18,944 metal helmets, and metal shields. 1014 00:37:19,029 --> 00:37:22,197 This would be a normal test in saladin's reign, 1015 00:37:22,282 --> 00:37:24,991 but I'm not in saladin's reign. 1016 00:37:25,077 --> 00:37:27,327 So I'm a little nervous. 1017 00:37:27,412 --> 00:37:30,372 [rock music] 1018 00:37:30,457 --> 00:37:34,084 ♪ ♪ 1019 00:37:34,962 --> 00:37:37,420 - wow. - [sighs] 1020 00:37:37,506 --> 00:37:38,755 - all right, bryan. 1021 00:37:38,840 --> 00:37:41,341 Blades this sharp and with this kind of edge geometry 1022 00:37:41,426 --> 00:37:44,594 often take a fairly substantial rolling 1023 00:37:44,680 --> 00:37:46,429 when they go up against armor. 1024 00:37:46,515 --> 00:37:47,764 Yours really didn't. 1025 00:37:47,849 --> 00:37:50,558 I mean, there's three spots I can feel 1026 00:37:50,644 --> 00:37:52,644 if I run my fingernail along it. 1027 00:37:52,729 --> 00:37:53,895 Just beautiful job. Well done. 1028 00:37:53,981 --> 00:37:54,980 - Thank you, sir. 1029 00:37:55,065 --> 00:37:56,523 - All right, walter. You're up. 1030 00:37:56,608 --> 00:37:58,066 - Let's do it. - [laughs] okay. 1031 00:37:58,151 --> 00:38:05,240 ♪ ♪ 1032 00:38:05,284 --> 00:38:06,741 - wow. 1033 00:38:06,785 --> 00:38:08,952 - Nice. 1034 00:38:09,037 --> 00:38:10,412 - All right, walter, 1035 00:38:10,497 --> 00:38:12,580 there's a little bit of a glinting, 1036 00:38:12,666 --> 00:38:14,416 and a little bit of a rough spot 1037 00:38:14,501 --> 00:38:16,459 here, here, and maybe here. 1038 00:38:16,545 --> 00:38:20,213 Other than that, this blade still has a wicked edge on it. 1039 00:38:20,299 --> 00:38:21,840 Curvature's really, really nice. 1040 00:38:21,925 --> 00:38:24,134 You nailed it. Scale, right on. 1041 00:38:24,219 --> 00:38:25,260 Well done. - Thank you, sir. 1042 00:38:25,345 --> 00:38:26,469 - You bet. 1043 00:38:26,513 --> 00:38:29,097 [dramatic music] 1044 00:38:29,182 --> 00:38:30,515 ♪ ♪ 1045 00:38:30,600 --> 00:38:32,392 - close race. 1046 00:38:32,477 --> 00:38:33,977 All right, bladesmiths, 1047 00:38:34,062 --> 00:38:36,062 welcome to the sharpness test. 1048 00:38:36,148 --> 00:38:38,315 To find out how sharp your weapons are, 1049 00:38:38,400 --> 00:38:39,649 I will take your weapon, 1050 00:38:39,735 --> 00:38:42,652 and I will cut through these egyptian rugs. 1051 00:38:42,696 --> 00:38:44,946 Now, I'm looking for clean cuts. 1052 00:38:45,032 --> 00:38:45,989 Bryan, you're up first. You ready? 1053 00:38:46,074 --> 00:38:47,615 - Yes, sir. - Let's do this. 1054 00:38:47,701 --> 00:38:50,618 ♪ ♪ 1055 00:38:50,662 --> 00:38:53,788 [rock music] 1056 00:38:53,874 --> 00:39:01,171 ♪ ♪ 1057 00:39:01,757 --> 00:39:04,174 all right, bryan, let's talk about your blade here. 1058 00:39:04,217 --> 00:39:06,760 It is razor sharp. 1059 00:39:06,845 --> 00:39:08,803 As I punctured and cut through the carpet, 1060 00:39:08,889 --> 00:39:10,889 there were very clean cuts. 1061 00:39:10,974 --> 00:39:12,766 Overall, sir, 1062 00:39:12,851 --> 00:39:14,100 your edge, it will cut. 1063 00:39:14,186 --> 00:39:15,226 - Thank you. 1064 00:39:15,312 --> 00:39:16,644 - All right, walter, you ready? 1065 00:39:16,730 --> 00:39:18,313 - Absolutely. - Let's do this. 1066 00:39:18,398 --> 00:39:25,362 ♪ ♪ 1067 00:39:27,240 --> 00:39:29,032 [sword rings] 1068 00:39:29,117 --> 00:39:30,992 listen to that ring. 1069 00:39:31,078 --> 00:39:35,121 ♪ ♪ 1070 00:39:35,207 --> 00:39:38,708 - all right, walter, let's talk about your weapon here. 1071 00:39:38,794 --> 00:39:40,418 Razor sharp. 1072 00:39:40,504 --> 00:39:42,379 It was easy to penetrate 1073 00:39:42,464 --> 00:39:44,547 and very easy to drag across. 1074 00:39:44,591 --> 00:39:47,384 These are very clean cuts. 1075 00:39:47,469 --> 00:39:50,220 Overall, sir, your weapon, it will cut. 1076 00:39:50,305 --> 00:39:51,888 - Thank you, sir. 1077 00:39:51,932 --> 00:39:54,849 [dramatic music] 1078 00:39:54,935 --> 00:39:56,393 ♪ ♪ 1079 00:39:56,478 --> 00:39:59,062 - well, guys, you both brought us immaculate weapons 1080 00:39:59,106 --> 00:40:01,773 that performed almost identically, 1081 00:40:01,858 --> 00:40:03,400 but the judges do need to make a decision 1082 00:40:03,443 --> 00:40:05,402 and choose which of you will be crowned 1083 00:40:05,487 --> 00:40:07,695 "forged in fire" champion. While we deliberate, 1084 00:40:07,781 --> 00:40:09,239 I'm gonna have to ask you to step off the forge floor. 1085 00:40:09,324 --> 00:40:11,324 - It's nerve-racking 1086 00:40:11,410 --> 00:40:13,535 being up against somebody who's as good as walter. 1087 00:40:13,620 --> 00:40:15,620 His work is extremely good, 1088 00:40:15,705 --> 00:40:18,748 and I'm very nervous going into this final judgement. 1089 00:40:18,834 --> 00:40:20,083 - We're so neck and neck, 1090 00:40:20,168 --> 00:40:21,584 I mean, we're literally like 1091 00:40:21,670 --> 00:40:23,378 two bulls with our horns locked in the field right now. 1092 00:40:23,463 --> 00:40:24,712 I don't know what's gonna happen. 1093 00:40:24,798 --> 00:40:26,214 ♪ ♪ 1094 00:40:26,299 --> 00:40:27,382 - well, guys, what do you think? 1095 00:40:27,467 --> 00:40:30,093 What I saw, that's about as close as it gets. 1096 00:40:30,178 --> 00:40:32,595 - These are two weapons that are so closely matched. 1097 00:40:32,681 --> 00:40:35,181 They're both beautifully made. 1098 00:40:35,267 --> 00:40:37,267 I think they tested out 1099 00:40:37,352 --> 00:40:39,394 virtually identically. 1100 00:40:39,479 --> 00:40:41,020 - Yeah. 1101 00:40:41,106 --> 00:40:44,149 - One blade stood out just a little bit 1102 00:40:44,234 --> 00:40:47,026 when I was doing the sharpness test 1103 00:40:47,112 --> 00:40:48,278 'cause it sang to me. 1104 00:40:48,321 --> 00:40:50,196 - Hearing it rip through the carpet 1105 00:40:50,282 --> 00:40:52,073 and the quintessential "bing." 1106 00:40:52,159 --> 00:40:54,117 okay, so you guys all on the same page then? 1107 00:40:54,202 --> 00:40:56,119 - I think so. - All right. 1108 00:40:56,204 --> 00:40:58,413 - I knew bryan was gonna be stiff competition, 1109 00:40:58,498 --> 00:41:00,999 and he absolutely brought it, 1110 00:41:01,084 --> 00:41:03,793 and I feel like I brought it too. 1111 00:41:03,837 --> 00:41:04,878 - All right, gentlemen, 1112 00:41:04,963 --> 00:41:05,962 the judges have made their decision. 1113 00:41:06,047 --> 00:41:07,755 Today's champion is... 1114 00:41:07,841 --> 00:41:10,091 ♪ ♪ 1115 00:41:10,177 --> 00:41:12,260 walter. 1116 00:41:12,345 --> 00:41:13,803 - Wait, what? [laughter] 1117 00:41:13,889 --> 00:41:16,222 I'm just in shock. [laughs] 1118 00:41:16,308 --> 00:41:17,474 I can't believe this. 1119 00:41:17,517 --> 00:41:18,766 - Now, unfortunately, bryan, 1120 00:41:18,852 --> 00:41:20,185 that means you did not win today. 1121 00:41:20,270 --> 00:41:21,978 - This is the closest decision 1122 00:41:22,063 --> 00:41:24,397 I have ever had to make, ever. 1123 00:41:24,483 --> 00:41:28,318 Bryan, you brought us an absolutely beautiful weapon. 1124 00:41:28,403 --> 00:41:29,861 It tested fantastically. 1125 00:41:29,946 --> 00:41:31,905 It felt fantastic in my hand. 1126 00:41:31,990 --> 00:41:35,366 We made this decision based on the smallest of details, 1127 00:41:35,452 --> 00:41:38,495 and it came down to the curvature of the blade. 1128 00:41:38,538 --> 00:41:41,581 Yours just has a little wobble in it, the other doesn't. 1129 00:41:41,666 --> 00:41:42,999 It's that close. 1130 00:41:43,043 --> 00:41:45,919 You should be incredibly proud of that blade, 1131 00:41:46,004 --> 00:41:48,588 and it was an absolute pleasure to be able to wield it. 1132 00:41:48,673 --> 00:41:50,548 - Thank you very much. 1133 00:41:50,634 --> 00:41:51,633 - Bryan, unfortunately, 1134 00:41:51,718 --> 00:41:53,051 that means you didn't make the cut today. 1135 00:41:53,094 --> 00:41:54,844 I'm gonna have to ask you to head off the forge floor. 1136 00:41:54,888 --> 00:41:57,597 - Bro, it's been an honor. 1137 00:41:57,682 --> 00:42:00,141 - I'm a little disappointed to not be in the winner's circle, 1138 00:42:00,227 --> 00:42:01,601 but very proud of the fact 1139 00:42:01,686 --> 00:42:03,061 that dave said it was one of the hardest decisions 1140 00:42:03,146 --> 00:42:04,312 they've ever had to make. 1141 00:42:04,397 --> 00:42:05,313 Feel I did pretty good. 1142 00:42:05,398 --> 00:42:07,065 ♪ ♪ 1143 00:42:07,150 --> 00:42:09,859 - well, walter, congratulations, buddy. 1144 00:42:09,945 --> 00:42:11,486 You are the "forged in fire" champion. 1145 00:42:11,530 --> 00:42:13,446 You'll be going out of here with a check for $10,000. 1146 00:42:13,532 --> 00:42:14,572 How do you feel? 1147 00:42:14,658 --> 00:42:15,949 - I don't even know right now. [laughs] 1148 00:42:16,034 --> 00:42:17,408 [laughter] I won. 1149 00:42:17,494 --> 00:42:19,702 [laughs] I can't believe it! 1150 00:42:19,788 --> 00:42:21,788 Ten grand is nothing to sneeze at, 1151 00:42:21,873 --> 00:42:23,540 but I wanna take a portion of it 1152 00:42:23,583 --> 00:42:26,167 and donate it to some kind of cancer organization. 1153 00:42:26,211 --> 00:42:28,211 Cancer's taken a lot of people away from me 1154 00:42:28,296 --> 00:42:29,462 that I care about. 1155 00:42:29,548 --> 00:42:30,964 It took my dad, 1156 00:42:31,049 --> 00:42:33,925 and I wanna be able to give back a little bit. 1157 00:42:34,010 --> 00:42:36,302 What a wild ride. [chuckles] 1158 00:42:36,388 --> 00:42:39,347 [rock music] 1159 00:42:39,432 --> 00:42:42,725 ♪ ♪