1 00:00:05,006 --> 00:00:07,798 [dramatic music] 2 00:00:07,883 --> 00:00:13,887 ♪ ♪ 3 00:00:13,973 --> 00:00:17,474 - my name is will morris. I'm 41 years old. 4 00:00:17,560 --> 00:00:19,268 What I love most about smithing 5 00:00:19,353 --> 00:00:21,270 is just getting into that zen moment. 6 00:00:21,355 --> 00:00:24,398 It's therapy really. 7 00:00:24,483 --> 00:00:27,026 - My name is josh wentz, 31 years old. 8 00:00:27,069 --> 00:00:28,819 I like to consider myself a full-time dad, 9 00:00:28,863 --> 00:00:30,154 part-time knife maker. 10 00:00:30,239 --> 00:00:32,156 There's a lot more time with my son 11 00:00:32,241 --> 00:00:33,532 than there is in my shop. 12 00:00:33,617 --> 00:00:34,825 I'm definitely not complaining. 13 00:00:34,869 --> 00:00:36,326 He's a ball of joy, 14 00:00:36,370 --> 00:00:38,662 and I'm happy every day that I get to be with him. 15 00:00:39,749 --> 00:00:41,874 - My name is menno, m-e-n-n-o, 16 00:00:41,959 --> 00:00:43,834 not like the fish. I sit on the phone all day. 17 00:00:43,919 --> 00:00:45,044 I say, "thank you for calling [indistinct]. 18 00:00:45,129 --> 00:00:47,004 This is menno." "like a fish?" 19 00:00:47,048 --> 00:00:49,590 "no, fish don't talk, man." [laughs] 20 00:00:49,675 --> 00:00:51,383 when I saw the show for the first time, 21 00:00:51,469 --> 00:00:54,053 I didn't know nothing about knife making, 22 00:00:54,096 --> 00:00:56,013 so I made a forge. 23 00:00:56,098 --> 00:00:57,556 I made a little sword out of a nail, 24 00:00:57,600 --> 00:01:00,684 cut myself with it, and I was intrigued. 25 00:01:00,770 --> 00:01:02,978 - My name's brad ditty. I'm 23 years old. 26 00:01:03,064 --> 00:01:05,022 Growing up, I always wanted to have a forge, 27 00:01:05,107 --> 00:01:06,440 but my dad would look at me and go, 28 00:01:06,525 --> 00:01:07,858 "I don't trust you with it." 29 00:01:07,943 --> 00:01:09,068 to be a "forged in fire" champion 30 00:01:09,153 --> 00:01:10,736 would make everyone at home proud, 31 00:01:10,780 --> 00:01:13,322 and that would just put a huge smile on my face. 32 00:01:13,407 --> 00:01:14,656 - Gentlemen, welcome to the forge. 33 00:01:14,742 --> 00:01:16,408 We're about to put you through the wringer 34 00:01:16,452 --> 00:01:18,327 in a forging competition unlike any other. 35 00:01:18,412 --> 00:01:20,079 At the end of each round, 36 00:01:20,164 --> 00:01:21,705 you'll be presenting your work for our panel of expert judges. 37 00:01:21,791 --> 00:01:24,458 Those judges today are blacksmith, bladesmith, 38 00:01:24,543 --> 00:01:27,002 and two-time "forged in fire" champion ben abbott, 39 00:01:27,088 --> 00:01:30,714 historic weapons re-creation specialist dave baker, 40 00:01:30,800 --> 00:01:32,091 and edge weapons specialist 41 00:01:32,176 --> 00:01:35,552 and kali martial artist doug marcaida. 42 00:01:35,638 --> 00:01:37,721 Now remember, the four of you are gonna be battling 43 00:01:37,807 --> 00:01:40,599 to figure out who's going home with the coveted title 44 00:01:40,643 --> 00:01:43,894 of "forged in fire" champion and that check for $10,000. 45 00:01:43,979 --> 00:01:45,104 In front of your anvils 46 00:01:45,189 --> 00:01:46,855 you guys have a sealed mission brief. 47 00:01:46,941 --> 00:01:51,026 Go ahead and open those up for me. 48 00:01:51,112 --> 00:01:54,571 We are calling this "mission: Zero." 49 00:01:54,657 --> 00:01:55,989 it's a brut de forge challenge. 50 00:01:56,075 --> 00:01:57,491 In round one of the competition, 51 00:01:57,576 --> 00:01:59,201 I want you guys to build me knives 52 00:01:59,286 --> 00:02:01,578 made out of this scrap metal here, 53 00:02:01,664 --> 00:02:03,497 but only during the salvaging period 54 00:02:03,582 --> 00:02:05,791 can you use tools to cut your steel. 55 00:02:05,876 --> 00:02:09,294 After that, no cutting tools, no grinders, no hot cutting. 56 00:02:09,380 --> 00:02:10,462 And obviously this means 57 00:02:10,506 --> 00:02:12,422 that every hammer strike is important. 58 00:02:12,508 --> 00:02:15,926 Any mistakes you have will end up in your final blade. 59 00:02:16,011 --> 00:02:17,719 So you also see in your mission briefs 60 00:02:17,805 --> 00:02:19,555 there is a volume calculating sheet. 61 00:02:19,640 --> 00:02:21,181 You can utilize that to figure out 62 00:02:21,267 --> 00:02:23,725 exactly how much steel you need to make your signature blades 63 00:02:23,811 --> 00:02:26,311 that meets these mission parameters. 64 00:02:26,355 --> 00:02:28,730 Your blade needs to be between 12" and 14" 65 00:02:28,816 --> 00:02:30,440 and have a full tang. 66 00:02:30,526 --> 00:02:32,442 - I'm european, and they don't mess 67 00:02:32,528 --> 00:02:33,819 with the calculations over there with here, 68 00:02:33,904 --> 00:02:35,362 so this is gonna be a tough one. 69 00:02:35,447 --> 00:02:37,114 - In round two of the competition, 70 00:02:37,199 --> 00:02:38,615 you guys are gonna be adding handles to your blades, 71 00:02:38,701 --> 00:02:40,492 making them fully functioning weapons. 72 00:02:40,578 --> 00:02:41,994 At that point, we will be testing them 73 00:02:42,079 --> 00:02:45,289 for strength and durability in an ammo can chop 74 00:02:45,332 --> 00:02:48,834 and checking your sharpness in a military bed slice. 75 00:02:48,919 --> 00:02:50,919 Now remember, you only have three hours in the first round 76 00:02:51,005 --> 00:02:52,671 of this competition, so good luck. 77 00:02:52,715 --> 00:02:54,506 Take your time. Make your calculations count. 78 00:02:54,592 --> 00:02:56,466 Your time starts now. 79 00:02:56,552 --> 00:03:00,012 ♪ ♪ 80 00:03:00,097 --> 00:03:02,556 would you guys be figuring out your calculations right now, 81 00:03:02,641 --> 00:03:04,683 or would you be looking at the metals first? 82 00:03:04,768 --> 00:03:06,643 - I would grab something that I knew was oversized 83 00:03:06,729 --> 00:03:08,312 that was not a ball bearing 84 00:03:08,397 --> 00:03:10,314 'cause cutting a third of that ball bearing off 85 00:03:10,399 --> 00:03:11,773 would be a real pain in the neck. 86 00:03:11,859 --> 00:03:14,902 - Look at the choices you have there and roll with it. 87 00:03:14,987 --> 00:03:16,862 - I've seen this competition a hundred times. 88 00:03:16,906 --> 00:03:19,114 Oh, my god. This is the hardest one ever. 89 00:03:19,200 --> 00:03:21,700 Looking at that paper, it's a lot of mumbo jumbo. 90 00:03:21,744 --> 00:03:24,036 It's hard for me because I don't have the skills 91 00:03:24,121 --> 00:03:26,038 in measuring because I'm european, 92 00:03:26,123 --> 00:03:29,875 but I'm getting used to the inches instead of centimeters. 93 00:03:29,919 --> 00:03:31,877 As I'm looking at the table, I can see a piece of steel 94 00:03:31,921 --> 00:03:35,505 and I think it's w4, and that is great metal. 95 00:03:35,591 --> 00:03:37,507 When I make a knife, I'm eyeballing everything. 96 00:03:37,593 --> 00:03:39,384 I'm not great at math, but I can put it in my hand 97 00:03:39,470 --> 00:03:41,178 and weigh it and know that it is too heavy, 98 00:03:41,263 --> 00:03:44,890 so I've cut off at least one fifth. 99 00:03:44,934 --> 00:03:47,309 - The amount of steel they start with is crucial 100 00:03:47,394 --> 00:03:48,644 because everything they start with 101 00:03:48,729 --> 00:03:50,270 is going to be in that final blade. 102 00:03:50,356 --> 00:03:51,688 And if they start with something too big, 103 00:03:51,774 --> 00:03:53,398 it's gonna be a boat anchor. 104 00:03:53,484 --> 00:03:55,859 - And that's it. 105 00:03:55,945 --> 00:03:57,236 - So I'm staring at the table, 106 00:03:57,321 --> 00:03:58,904 and I'm feeling a little bit of angst in my gut. 107 00:03:58,948 --> 00:04:01,740 Which one is gonna be the best steel for me to use? 108 00:04:01,784 --> 00:04:03,992 And immediately I'm thinking it's the leaf spring. 109 00:04:04,078 --> 00:04:05,786 The 7" piece would be more than enough 110 00:04:05,871 --> 00:04:07,162 to do what I'm doing. 111 00:04:07,248 --> 00:04:09,081 - Brad just shot himself in the foot. 112 00:04:09,166 --> 00:04:11,583 He cut off about a 4-inch piece of that. 113 00:04:11,669 --> 00:04:13,210 That is gonna be one lean knife. 114 00:04:13,295 --> 00:04:15,295 - Some bladesmiths that I've seen are very precise 115 00:04:15,381 --> 00:04:17,089 in every measurement in everything they do, 116 00:04:17,132 --> 00:04:18,423 but that's just not me. 117 00:04:18,467 --> 00:04:19,508 - Pretty confident. 118 00:04:19,593 --> 00:04:20,509 Usually I'm good at eyeballing stuff. 119 00:04:20,594 --> 00:04:21,760 I never measure at home, 120 00:04:21,804 --> 00:04:23,053 so going by the seat of my pants. 121 00:04:23,138 --> 00:04:24,554 I know it isn't always the best thing to do, 122 00:04:24,640 --> 00:04:26,223 but it's how I'm doing it right now. 123 00:04:26,308 --> 00:04:29,268 - The whole idea behind a brut de forge knife is no grinding, 124 00:04:29,353 --> 00:04:32,145 so now I'm gonna have to rely on my hammer for everything. 125 00:04:32,231 --> 00:04:33,772 I tried to figure out the equation, 126 00:04:33,816 --> 00:04:35,107 but it looks like chinese, 127 00:04:35,192 --> 00:04:37,401 so I decide to just give it my best guess. 128 00:04:37,444 --> 00:04:38,902 - What is the formula? 129 00:04:38,988 --> 00:04:42,281 - The sphere is 4/3 pi r cubed, and then anything square 130 00:04:42,324 --> 00:04:44,449 is you multiply all three dimensions together. 131 00:04:44,493 --> 00:04:46,076 - Nerd alert. - [laughs] 132 00:04:46,161 --> 00:04:48,120 - I see some round stock that is a little skinnier, 133 00:04:48,205 --> 00:04:50,122 and I think it's going to be perfect for the challenge. 134 00:04:50,165 --> 00:04:51,456 - It looks like josh 135 00:04:51,500 --> 00:04:53,750 is not cutting anything off that round stock. 136 00:04:53,836 --> 00:04:55,294 - I weld my stick to my steel 137 00:04:55,337 --> 00:04:56,670 and then muscle memory kicks in. 138 00:04:56,755 --> 00:04:58,422 I throw it right into the forge. 139 00:04:58,507 --> 00:05:01,133 - He's probably got almost two pounds of metal there. 140 00:05:01,176 --> 00:05:02,759 - [bleep]. 141 00:05:02,803 --> 00:05:04,094 It dawns on me that I forgot 142 00:05:04,138 --> 00:05:06,138 to cut any excess material off. 143 00:05:06,181 --> 00:05:08,265 - We always say it's good to have sacrificial steel. 144 00:05:08,350 --> 00:05:10,183 Not in this challenge. We're gonna have to judge you 145 00:05:10,269 --> 00:05:13,020 based on what you actually forge to shape. 146 00:05:13,105 --> 00:05:14,771 - Starting over was not an option for me. 147 00:05:14,857 --> 00:05:16,940 I'd rather have more than enough material 148 00:05:17,026 --> 00:05:18,483 than not enough material. 149 00:05:18,527 --> 00:05:20,652 Just hope it doesn't come back to bite me in the butt. 150 00:05:20,738 --> 00:05:22,362 - I'm gonna pick the round stock, 151 00:05:22,448 --> 00:05:24,406 and I'm looking at the sheet of paper, 152 00:05:24,491 --> 00:05:25,824 and I can tell you right now 153 00:05:25,909 --> 00:05:27,617 I'm not gonna sit here and try to do math. 154 00:05:27,661 --> 00:05:29,244 I'm just gonna go with my gut. 155 00:05:29,330 --> 00:05:31,621 - So it seems like the guys are just going with it. 156 00:05:31,707 --> 00:05:33,040 Do you think 157 00:05:33,083 --> 00:05:34,416 there's something to be said about just winging it? 158 00:05:34,501 --> 00:05:36,793 - In this competition, if you were given the ability 159 00:05:36,879 --> 00:05:40,130 to measure everything, they've got scales out there, 160 00:05:40,215 --> 00:05:43,550 the steel is about 4.6 ounces per cubic inch, 161 00:05:43,635 --> 00:05:44,968 cut 'til you have that exact amount of steel, 162 00:05:45,054 --> 00:05:46,219 and then go for it. 163 00:05:46,305 --> 00:05:47,846 - My gut could be lying to me today, 164 00:05:47,890 --> 00:05:52,184 and I could be way undersized on my steel or way oversized. 165 00:05:52,227 --> 00:05:53,727 It's a risk I'm willing to take. 166 00:05:53,812 --> 00:05:55,062 Let's see if it pays off. 167 00:05:55,147 --> 00:05:57,522 Hot. Whoo-hoo. 168 00:05:57,566 --> 00:06:00,859 - I am making a big chopper. There's just so much metal. 169 00:06:00,903 --> 00:06:04,571 The chopper is the best knife you can make. 170 00:06:04,656 --> 00:06:06,990 But right now I'm going from big blu to the press 171 00:06:07,076 --> 00:06:10,243 back to measuring, big blu, press. 172 00:06:10,329 --> 00:06:12,204 It is very difficult to have no grinders 173 00:06:12,247 --> 00:06:14,706 because you cannot grind it to a specific way 174 00:06:14,750 --> 00:06:16,875 that you want to have the knife look. 175 00:06:16,960 --> 00:06:19,586 But it doesn't matter. This is the big leagues. 176 00:06:19,671 --> 00:06:22,214 I'm super happy with my blade. It's the right size. 177 00:06:22,299 --> 00:06:24,383 It's the right width. It's the right weight. 178 00:06:24,426 --> 00:06:26,385 I think they're gonna love it, and it will cut. 179 00:06:26,470 --> 00:06:27,719 For this challenge, 180 00:06:27,763 --> 00:06:29,179 I'm looking to make a clip point camp knife. 181 00:06:29,264 --> 00:06:30,639 It's gonna have a wider edge. 182 00:06:30,724 --> 00:06:32,474 It's gonna be good for thrusting and for slashing. 183 00:06:32,559 --> 00:06:34,893 - So if I were brad with the steel he's got, 184 00:06:34,978 --> 00:06:38,730 I'd start with the ideal shape for that. 185 00:06:38,774 --> 00:06:40,399 - I got to be careful drawing it out 186 00:06:40,442 --> 00:06:42,692 'cause I can't cut anything off. 187 00:06:42,778 --> 00:06:44,027 So at my home forge, 188 00:06:44,113 --> 00:06:45,404 I don't like to stand there and do nothing, 189 00:06:45,447 --> 00:06:47,030 so sometimes I wiggle, sometimes I dance. 190 00:06:47,116 --> 00:06:48,407 - [laughs] - oh, I like it. 191 00:06:48,450 --> 00:06:50,742 - And sometimes I talk to myself and answer back. 192 00:06:50,786 --> 00:06:52,244 [high-pitched voice] okay. Okay. One more time. 193 00:06:52,329 --> 00:06:53,995 I put it back in this way. 194 00:06:54,081 --> 00:06:55,288 [normal voice] I like to have a lot of fun with it. 195 00:06:55,374 --> 00:06:57,040 [high-pitched voice] we can do it. 196 00:06:57,126 --> 00:06:59,209 - Bladesmiths, you have two hours remaining. 197 00:06:59,294 --> 00:07:01,253 - So now I'm stuck with this huge piece of steel. 198 00:07:01,338 --> 00:07:03,880 My plan is to at least get that to the parameters, 199 00:07:03,966 --> 00:07:06,049 then put all the extra into the handle. 200 00:07:06,135 --> 00:07:08,218 ♪ ♪ 201 00:07:08,303 --> 00:07:10,220 whoo. [bleep]. 202 00:07:10,264 --> 00:07:13,098 I pinched my steel. Bad news is I got a cold shut. 203 00:07:13,142 --> 00:07:14,599 Yeah, it's frustrating that you look over 204 00:07:14,685 --> 00:07:17,227 and you see a perfectly good grinder sitting there. 205 00:07:17,312 --> 00:07:18,603 Any other day 206 00:07:18,689 --> 00:07:20,188 I could go over there and just grind that off, 207 00:07:20,274 --> 00:07:21,440 but we're not allowed to do that. 208 00:07:21,525 --> 00:07:23,233 Luckily I can put that on my spine 209 00:07:23,277 --> 00:07:25,152 early enough to work around it. 210 00:07:25,237 --> 00:07:27,737 - It looks like he has a lot of steel on that working stick. 211 00:07:27,823 --> 00:07:30,323 - He started out with that 6" x 1 1/4", 212 00:07:30,409 --> 00:07:33,618 and now he has 10" x 1 1/4". [laughs] 213 00:07:33,662 --> 00:07:35,454 - I'm hammering in the bevels, 214 00:07:35,539 --> 00:07:37,789 and the steel's not moving the way I want it to. 215 00:07:37,875 --> 00:07:39,207 I'm having a really hard time. 216 00:07:39,293 --> 00:07:40,709 Yeah, like trigger finger. 217 00:07:40,794 --> 00:07:42,252 I'm cramping up like crazy. 218 00:07:42,337 --> 00:07:44,379 I'm throwing gang signs without even trying. 219 00:07:44,465 --> 00:07:46,089 [grunts] 220 00:07:46,175 --> 00:07:49,009 I probably can't even tie my shoe at this point, 221 00:07:49,094 --> 00:07:51,344 but I'm not gonna quit. [sighs] 222 00:07:51,430 --> 00:07:54,473 I'm a very stubborn person, and I don't give in. 223 00:07:54,516 --> 00:07:56,475 So I'm gonna go to the drill press, 224 00:07:56,560 --> 00:07:58,477 and that should give my arms a break 225 00:07:58,520 --> 00:08:01,354 so I can go back to swinging a hammer. 226 00:08:01,440 --> 00:08:02,355 - They didn't lie about the heat. 227 00:08:02,441 --> 00:08:03,565 - No. 228 00:08:03,650 --> 00:08:05,609 - I'm having a blast, but I'm feeling like 229 00:08:05,694 --> 00:08:08,069 a little bit the old dog because these guys are younger. 230 00:08:08,155 --> 00:08:09,821 I think I lost a few pounds today. 231 00:08:09,865 --> 00:08:10,947 - Hell yeah. 232 00:08:11,033 --> 00:08:12,449 - I am very talkative when I'm forging. 233 00:08:12,534 --> 00:08:14,117 - Menno was talking to me a lot, 234 00:08:14,203 --> 00:08:15,619 but I have headphones on. 235 00:08:15,704 --> 00:08:17,913 So there's some things I heard, but most of the time, 236 00:08:17,998 --> 00:08:19,289 I can't hear what anybody's saying, 237 00:08:19,374 --> 00:08:21,458 so I'm just like, "okay." 238 00:08:21,502 --> 00:08:22,918 as I'm in the press, 239 00:08:23,003 --> 00:08:24,586 I'm realizing that I'm not gonna have the width 240 00:08:24,671 --> 00:08:26,129 I need to make a camp knife. 241 00:08:26,215 --> 00:08:27,964 - We got two bladesmiths who seem like 242 00:08:28,050 --> 00:08:29,341 they've got too much steel. 243 00:08:29,384 --> 00:08:31,676 Then we got brad who cut way too much off. 244 00:08:31,762 --> 00:08:33,512 - Do I go to the table and get more steel? 245 00:08:33,555 --> 00:08:36,139 At this moment I realize that my knife depends 246 00:08:36,225 --> 00:08:37,974 on my decision right now. 247 00:08:38,060 --> 00:08:40,435 This is the tipping point for me in the challenge. 248 00:08:40,521 --> 00:08:41,686 Uh... 249 00:08:41,772 --> 00:08:43,480 If I start over, I risk not making it. 250 00:08:43,565 --> 00:08:48,151 I am extremely nervous. 251 00:08:48,278 --> 00:08:49,986 - I'm realizing that I'm not gonna have the width 252 00:08:50,030 --> 00:08:50,820 I need to make a camp knife. 253 00:08:50,906 --> 00:08:53,114 I risk not making it. 254 00:08:53,200 --> 00:08:54,616 If I go through with this, 255 00:08:54,701 --> 00:08:56,618 I have to make sure whatever I do is pretty darn good. 256 00:08:56,703 --> 00:08:58,245 So I need to have something that's gonna have 257 00:08:58,288 --> 00:09:00,497 a lot of strength in the spine but have a good cutting edge, 258 00:09:00,582 --> 00:09:03,625 and immediately what comes to mind is a japanese wakizashi. 259 00:09:03,710 --> 00:09:06,169 A japanese wakizashi has a slight curve to it. 260 00:09:06,255 --> 00:09:07,337 It's good for slashing, 261 00:09:07,422 --> 00:09:10,298 and it's got a very thick spine to it. 262 00:09:10,384 --> 00:09:12,676 I'm doing my very best to create a perfect 263 00:09:12,761 --> 00:09:14,219 and symmetrical edge down the center 264 00:09:14,263 --> 00:09:16,763 and also keep the spine nice and thick. 265 00:09:16,848 --> 00:09:18,223 As I'm looking at my blade now, 266 00:09:18,267 --> 00:09:20,559 I am so happy that I went with the decision. 267 00:09:20,602 --> 00:09:22,561 It looks pretty darn good. 268 00:09:22,604 --> 00:09:23,853 - So I've got about an hour left. 269 00:09:23,939 --> 00:09:25,188 Normally I would step over to the grinder 270 00:09:25,274 --> 00:09:27,232 and start getting that edge thickness down 271 00:09:27,276 --> 00:09:28,483 to where I want it, but instead, 272 00:09:28,569 --> 00:09:30,735 I'm sitting here planishing my steel. 273 00:09:30,779 --> 00:09:32,028 I'm just trying to get all the rough hammer marks 274 00:09:32,072 --> 00:09:33,238 out of her right now. 275 00:09:33,323 --> 00:09:35,532 Definitely seen the judges pick that out. 276 00:09:35,617 --> 00:09:38,326 Last year I made the change to become a fulltime knife maker, 277 00:09:38,412 --> 00:09:39,786 so if it wasn't for my wife, 278 00:09:39,871 --> 00:09:41,871 I would never have the chance to do this. 279 00:09:41,957 --> 00:09:45,208 Win or lose, I just want to finish for my wife. 280 00:09:45,294 --> 00:09:48,753 - I got my holes drilled, so I'm gonna switch gears. 281 00:09:48,839 --> 00:09:51,381 As I'm hammering on the steel, I'm actually planishing out 282 00:09:51,466 --> 00:09:54,092 some of the hammer marks I did prior. 283 00:09:54,136 --> 00:09:55,677 - So you know what I noticed that will was doing? 284 00:09:55,762 --> 00:09:58,597 He was hammering the shape of his blade 285 00:09:58,682 --> 00:10:00,223 when there was no more color to it. 286 00:10:00,309 --> 00:10:03,268 Is there a risk that he could add some cracks to that? 287 00:10:03,312 --> 00:10:04,894 - Certainly cracking is an issue 288 00:10:04,980 --> 00:10:06,271 when you run out of color in a blade. 289 00:10:06,315 --> 00:10:08,231 - Knowing that I'm having a really hard time 290 00:10:08,275 --> 00:10:10,150 swinging the hammer, 291 00:10:10,235 --> 00:10:12,110 I don't think I can really do too much else. 292 00:10:12,195 --> 00:10:13,528 Whoo-ee! 293 00:10:13,614 --> 00:10:15,280 I'm gonna quench it, hope it's hard, 294 00:10:15,365 --> 00:10:17,949 hope it's straight, go from there. 295 00:10:17,993 --> 00:10:20,243 - 20 minutes remaining, bladesmiths. 296 00:10:20,329 --> 00:10:22,412 - Now that I'm getting ready for the quench, 297 00:10:22,497 --> 00:10:25,457 I make sure that my temperatures are good. 298 00:10:25,500 --> 00:10:26,958 [fire whooshes] 299 00:10:27,044 --> 00:10:29,461 - menno quenched that blade way too hot 300 00:10:29,504 --> 00:10:32,255 and then took it out while it was still way too hot. 301 00:10:32,341 --> 00:10:33,423 - [grunts] 302 00:10:33,508 --> 00:10:34,799 in the front it's good, 303 00:10:34,843 --> 00:10:36,926 but in the back by the handle, it's not hard. 304 00:10:37,012 --> 00:10:38,762 [dramatic musical sting] 305 00:10:38,805 --> 00:10:41,056 - he doesn't look like he's happy right now, guys. 306 00:10:41,141 --> 00:10:43,141 - You could see when he was filing, he was biting into it. 307 00:10:43,185 --> 00:10:46,645 - So I make the decision to do another quench. 308 00:10:46,730 --> 00:10:48,146 I hate to do it. 309 00:10:48,231 --> 00:10:50,273 The possibility that it breaks on the second quench 310 00:10:50,359 --> 00:10:53,026 could happen, so it has to be perfect. 311 00:10:53,111 --> 00:10:54,444 - Oh, wow. That's bright. 312 00:10:54,529 --> 00:10:56,237 [laughing] it's gonna burst into flames. 313 00:10:56,323 --> 00:10:59,491 ♪ ♪ 314 00:10:59,576 --> 00:11:01,618 - that's hard. I'm so happy. 315 00:11:01,703 --> 00:11:03,912 I will be surprised if I don't go through the next round 316 00:11:03,997 --> 00:11:06,456 'cause it's a beautiful blade. 317 00:11:06,541 --> 00:11:08,124 - Now that my blade fits the parameters 318 00:11:08,210 --> 00:11:10,126 and has a nice shape to it, I'm getting ready to quench. 319 00:11:10,212 --> 00:11:13,838 ♪ ♪ 320 00:11:13,882 --> 00:11:15,131 and it's not hard. 321 00:11:15,175 --> 00:11:16,716 [bleep]. 322 00:11:16,802 --> 00:11:18,760 At this moment I am really kind of let down, 323 00:11:18,845 --> 00:11:20,762 but it's not time to give up. 324 00:11:20,847 --> 00:11:23,515 - Brad's back in the forge after he quenched. 325 00:11:23,600 --> 00:11:25,892 - Re-quenching might affect my blade in the testing, 326 00:11:25,977 --> 00:11:27,644 but it's up to god, not me. 327 00:11:27,729 --> 00:11:30,647 ♪ ♪ 328 00:11:30,732 --> 00:11:33,191 I run the file across it, and it skates. 329 00:11:33,276 --> 00:11:35,610 Thank you, jesus. [laughs] 330 00:11:35,696 --> 00:11:38,863 - I'm ready to finally quench this knife. 331 00:11:38,907 --> 00:11:40,448 - Josh is quenched. 332 00:11:40,534 --> 00:11:41,950 - Before I even look at it, 333 00:11:42,035 --> 00:11:43,535 I run over to the straightening jig. 334 00:11:43,578 --> 00:11:47,372 I let it sit and cool, and luckily it's nice and hard. 335 00:11:47,416 --> 00:11:49,207 It's straight. It's still heavy, 336 00:11:49,251 --> 00:11:50,792 but I couldn't have asked for anything more. 337 00:11:50,877 --> 00:11:52,460 Oh, my god. Whew. 338 00:11:52,546 --> 00:11:54,379 - Ten minutes on the clock, guys. 339 00:11:54,423 --> 00:11:55,672 - I don't have all day, 340 00:11:55,757 --> 00:11:57,841 so it's time to start quenching. 341 00:11:57,884 --> 00:11:59,384 Get it up to critical temp, 342 00:11:59,428 --> 00:12:01,594 and then into the oil for the quench. 343 00:12:01,680 --> 00:12:05,098 No tings, no cracks. I feel really good about it. 344 00:12:05,183 --> 00:12:06,975 - Five. Four. 345 00:12:07,060 --> 00:12:09,602 Three. Two. One. 346 00:12:09,688 --> 00:12:11,980 Put down your tools. This round is over. 347 00:12:12,065 --> 00:12:13,898 - Looking down and seeing what I produced, 348 00:12:13,984 --> 00:12:16,025 regardless of what the judges decide, 349 00:12:16,111 --> 00:12:20,029 I'm happy with what I did. It's been awesome. 350 00:12:20,115 --> 00:12:22,407 - All right, guys, in objective one of mission: Zero, 351 00:12:22,451 --> 00:12:23,992 you were tasked to source your steel, 352 00:12:24,077 --> 00:12:25,577 calculating the precise amount 353 00:12:25,662 --> 00:12:27,203 you wanted to make your end blade. 354 00:12:27,289 --> 00:12:29,456 Unfortunately we're gonna have to send somebody home 355 00:12:29,541 --> 00:12:30,874 before we go into round two. 356 00:12:30,959 --> 00:12:32,500 Let's see what the judges have to say. 357 00:12:32,586 --> 00:12:33,585 Will, you ready? - Yes, sir. 358 00:12:33,670 --> 00:12:34,836 - Please present your work. 359 00:12:34,921 --> 00:12:37,088 [tense music] 360 00:12:37,132 --> 00:12:38,923 - all right, will. You've got a basic knife shape here. 361 00:12:39,009 --> 00:12:41,885 I'd say, though, the one thing that gives me the most pause 362 00:12:41,970 --> 00:12:45,138 is there's a crack right here that comes in, 363 00:12:45,223 --> 00:12:46,598 rolls around the edge, 364 00:12:46,641 --> 00:12:48,057 and comes in a similar amount on this side. 365 00:12:48,101 --> 00:12:50,018 I would be nervous if were to try to test this 366 00:12:50,103 --> 00:12:52,187 of that just letting go. 367 00:12:52,272 --> 00:12:53,313 - All right, josh, you're up next. 368 00:12:53,356 --> 00:12:56,399 Please present your work to the judges. 369 00:12:56,485 --> 00:12:58,234 - So the overall shape of your blade, 370 00:12:58,320 --> 00:13:00,028 I like the profile look, 371 00:13:00,113 --> 00:13:02,113 but there's so much weight here. 372 00:13:02,199 --> 00:13:03,531 It's very thick. 373 00:13:03,617 --> 00:13:07,744 But what I like about it is that you aptly tapered it. 374 00:13:07,829 --> 00:13:11,039 So what that does is it really gives all the weight back here 375 00:13:11,124 --> 00:13:14,209 and not in front of the blade so it's easier to move. 376 00:13:14,294 --> 00:13:17,712 A lot of metal to remove, but overall good job. 377 00:13:17,798 --> 00:13:19,589 - Thanks. - All right, menno, you're up. 378 00:13:19,674 --> 00:13:21,049 Please present your work. 379 00:13:21,134 --> 00:13:23,259 ♪ ♪ 380 00:13:23,345 --> 00:13:24,761 - all right, menno, let's talk about your blade here. 381 00:13:24,846 --> 00:13:26,513 I do like the profile you have. 382 00:13:26,598 --> 00:13:28,306 Actually I like the dimensions of your handle. 383 00:13:28,391 --> 00:13:30,517 It fits nicely in my hand. 384 00:13:30,602 --> 00:13:31,726 But the minute I pick it up, 385 00:13:31,812 --> 00:13:34,145 I can feel all the weight up here. 386 00:13:34,231 --> 00:13:35,730 It's not evenly distributed. 387 00:13:35,816 --> 00:13:37,774 You could have tapered your blade, 388 00:13:37,859 --> 00:13:39,692 but moving forward, there's a lot of grinding, 389 00:13:39,778 --> 00:13:43,279 a lot of refining, but overall good job. 390 00:13:43,323 --> 00:13:46,115 - Thank you. - All right, brad, you ready? 391 00:13:46,201 --> 00:13:47,283 Please present your work. 392 00:13:47,369 --> 00:13:49,577 ♪ ♪ 393 00:13:49,663 --> 00:13:51,579 - you played the game to a tee. 394 00:13:51,665 --> 00:13:53,581 You made a great calculation, 395 00:13:53,667 --> 00:13:54,916 and you turned that calculation 396 00:13:55,001 --> 00:13:57,210 into a fully functional blade as it is. 397 00:13:57,295 --> 00:13:58,795 You could grind an edge onto this 398 00:13:58,880 --> 00:14:01,422 and have an absolutely functional blade 399 00:14:01,508 --> 00:14:03,132 without changing anything else. 400 00:14:03,218 --> 00:14:04,634 Moving forward, 401 00:14:04,719 --> 00:14:07,512 I would be careful not to bulk the handle up too much. 402 00:14:07,556 --> 00:14:11,724 As is, this is a really classic, 403 00:14:11,810 --> 00:14:14,561 modern tonto fighter kind of feel to it, 404 00:14:14,646 --> 00:14:17,021 and I think you did just a fantastic job. 405 00:14:17,065 --> 00:14:18,273 Well done. 406 00:14:18,358 --> 00:14:19,649 - All right, you all did very well 407 00:14:19,734 --> 00:14:21,109 in the brut de forge challenge, 408 00:14:21,194 --> 00:14:22,944 but unfortunately one of you will not be moving forward 409 00:14:23,029 --> 00:14:24,612 into round two of the competition. 410 00:14:24,698 --> 00:14:26,489 The bladesmith not moving forward is... 411 00:14:26,575 --> 00:14:28,032 ♪ ♪ 412 00:14:28,118 --> 00:14:29,367 will. 413 00:14:29,411 --> 00:14:30,827 Dave baker is gonna tell you why. 414 00:14:30,912 --> 00:14:33,538 - So, will, you did a great job hammering out that blade, 415 00:14:33,582 --> 00:14:35,790 but that large crack running right across 416 00:14:35,876 --> 00:14:37,625 the edge of the blade, as deep as it is, 417 00:14:37,711 --> 00:14:39,002 puts the structure of that blade in question, 418 00:14:39,087 --> 00:14:40,962 and that's why we're letting you go. 419 00:14:41,047 --> 00:14:42,505 - I totally understand. Thank you. 420 00:14:42,591 --> 00:14:44,048 - All right, will, thanks for your hard work, 421 00:14:44,134 --> 00:14:46,050 but it's time to ask you to please surrender your weapon 422 00:14:46,094 --> 00:14:47,427 and leave the forge floor. 423 00:14:47,512 --> 00:14:49,596 - I'm disappointed, but I can't control that crack. 424 00:14:49,681 --> 00:14:51,681 Getting mad over it isn't gonna change the fact 425 00:14:51,725 --> 00:14:53,224 that there's a crack. 426 00:14:53,310 --> 00:14:55,310 The challenge was actually a lot more demanding 427 00:14:55,395 --> 00:14:56,978 than I thought, but you know, 428 00:14:57,063 --> 00:14:59,355 life always has a plan for you. You may not see it, 429 00:14:59,441 --> 00:15:01,149 but it reveals itself over time, 430 00:15:01,234 --> 00:15:03,526 so I'm okay with it. 431 00:15:03,612 --> 00:15:04,861 - Congratulations. 432 00:15:04,946 --> 00:15:06,487 You guys are moving into round two. 433 00:15:06,573 --> 00:15:07,906 In front of you, you've got ammo cans. 434 00:15:07,991 --> 00:15:09,991 Go ahead and open them up and check out what's inside. 435 00:15:10,076 --> 00:15:11,826 ♪ ♪ 436 00:15:11,912 --> 00:15:14,579 inside is everything you will need to complete round two. 437 00:15:14,664 --> 00:15:15,580 There is a bunch of scales. 438 00:15:15,665 --> 00:15:17,540 You got different handle materials. 439 00:15:17,626 --> 00:15:19,542 You've got your pins. You've got your epoxies. 440 00:15:19,628 --> 00:15:22,462 You will also see a bunch of spent ammo casings. 441 00:15:22,547 --> 00:15:24,839 I want you guys to integrate those into the construction 442 00:15:24,925 --> 00:15:26,799 of your handles in some way, shape, or form. 443 00:15:26,885 --> 00:15:29,052 We will be testing them for strength and durability 444 00:15:29,137 --> 00:15:31,179 in an ammo can chop 445 00:15:31,264 --> 00:15:34,974 and checking your sharpness in a military bed slice. 446 00:15:35,060 --> 00:15:36,351 Best news yet, 447 00:15:36,436 --> 00:15:39,228 you guys have access to the grinders in this round. 448 00:15:39,314 --> 00:15:41,397 You guys only have two hours, so good luck. 449 00:15:41,441 --> 00:15:43,691 Your time starts now. 450 00:15:43,777 --> 00:15:47,570 ♪ ♪ 451 00:15:47,656 --> 00:15:49,030 - this better turn into grinder fest. 452 00:15:49,115 --> 00:15:50,698 - So many bullets. 453 00:15:50,784 --> 00:15:53,910 I have to include a bullet round casing into my handle. 454 00:15:53,995 --> 00:15:55,370 How am I gonna do this? 455 00:15:55,455 --> 00:15:56,788 - Throwing in the bullet casings, 456 00:15:56,831 --> 00:15:58,289 what would you guys be planning to do with it? 457 00:15:58,333 --> 00:16:00,083 - You can just drill a hole through both tangs 458 00:16:00,168 --> 00:16:02,919 and just cut a casing that fits out flush on either side. 459 00:16:03,004 --> 00:16:05,380 You could also make an actual cutlers rivet out of it 460 00:16:05,465 --> 00:16:07,090 where you crimp one of the casings 461 00:16:07,175 --> 00:16:08,466 and you put it inside the other, 462 00:16:08,510 --> 00:16:10,802 and from both sides smash them together. 463 00:16:10,887 --> 00:16:13,596 - As I'm staring at my table, I notice that there is a short 464 00:16:13,682 --> 00:16:15,890 .22 shell and a long one. 465 00:16:15,976 --> 00:16:18,518 If these can go together, maybe I can pinch the one end. 466 00:16:18,603 --> 00:16:20,186 I can turn this into a tube 467 00:16:20,271 --> 00:16:22,605 instead of a shell and use it as a pin. 468 00:16:22,691 --> 00:16:25,942 - Well, brad's using the caps as a sort of a decorative pin. 469 00:16:26,027 --> 00:16:28,653 We all know how thin the back end of a bullet is, 470 00:16:28,697 --> 00:16:30,989 so he could easily grind that away. 471 00:16:31,074 --> 00:16:33,992 - Ha. Yes. And they fit perfectly. 472 00:16:34,035 --> 00:16:35,493 I couldn't ask for anything better. 473 00:16:35,537 --> 00:16:37,620 All right. 474 00:16:37,706 --> 00:16:38,830 - All right. 475 00:16:38,873 --> 00:16:40,331 I wanted to make the nicest handles 476 00:16:40,375 --> 00:16:42,333 out of the pantry, not with these things. 477 00:16:42,377 --> 00:16:44,335 I immediately see the .22 shells, 478 00:16:44,379 --> 00:16:46,796 and I hope that's gonna be the same size as my holes. 479 00:16:46,881 --> 00:16:48,464 ♪ ♪ 480 00:16:48,508 --> 00:16:49,841 perfect. 481 00:16:49,884 --> 00:16:51,968 - I saw menno grabbing through the ammo. 482 00:16:52,053 --> 00:16:53,678 It looked like he picked one round up 483 00:16:53,763 --> 00:16:55,763 and it fit almost perfectly. 484 00:16:55,849 --> 00:16:57,181 - Whew. 485 00:16:57,225 --> 00:16:58,683 The bullet shells that I'm using 486 00:16:58,768 --> 00:17:00,935 do three pin stalks in it with glue, 487 00:17:01,021 --> 00:17:02,520 so that is the end of a pin stock. 488 00:17:02,605 --> 00:17:04,313 It's more like a corby bolt. 489 00:17:04,399 --> 00:17:07,108 Then I can go immediately to the grinder. 490 00:17:07,193 --> 00:17:08,776 ♪ ♪ 491 00:17:08,862 --> 00:17:11,404 oh, my god, I'm so happy that we could use all the tools. 492 00:17:11,489 --> 00:17:14,323 The grinders are, for me, valhalla. 493 00:17:14,409 --> 00:17:16,284 I have to take so much metal off 494 00:17:16,369 --> 00:17:18,411 because it's so heavy. 495 00:17:18,496 --> 00:17:19,662 This has to be perfect. 496 00:17:19,748 --> 00:17:21,330 ♪ ♪ 497 00:17:21,416 --> 00:17:22,957 - [grunts] 498 00:17:23,043 --> 00:17:25,501 - josh has such a thick tang. 499 00:17:25,587 --> 00:17:27,795 I would love to see that cut in half at least. 500 00:17:27,881 --> 00:17:29,672 ♪ ♪ 501 00:17:29,716 --> 00:17:31,841 - I'm gonna address the handle length 502 00:17:31,926 --> 00:17:34,552 and then address the handle shape later. 503 00:17:34,637 --> 00:17:36,054 Good. 504 00:17:36,139 --> 00:17:38,139 - Josh just went and cut off the back half of his handle. 505 00:17:38,224 --> 00:17:39,891 - Perfect. That's what he needed to do. 506 00:17:39,934 --> 00:17:44,395 - I've got to adjust my handle so the judges feel more secure 507 00:17:44,439 --> 00:17:46,731 holding that knife in their hand. 508 00:17:46,775 --> 00:17:51,069 - Bladesmiths, you guys have one hour remaining. 509 00:17:51,112 --> 00:17:52,403 - Try this one. 510 00:17:52,447 --> 00:17:55,907 I'm looking, I see acrylic, horn, and micarta. 511 00:17:55,950 --> 00:17:57,742 I could probably cut the micarta 512 00:17:57,786 --> 00:17:59,160 and not worry about any brittleness from it 513 00:17:59,245 --> 00:18:01,454 because micarta is actually very strong. 514 00:18:01,539 --> 00:18:04,040 About halfway through the block, it starts to kick. 515 00:18:04,125 --> 00:18:05,541 ♪ ♪ 516 00:18:05,585 --> 00:18:07,168 that didn't work at all. 517 00:18:07,253 --> 00:18:08,836 So I grab the acrylic, which I've used, 518 00:18:08,922 --> 00:18:10,046 but however I know is very brittle, 519 00:18:10,131 --> 00:18:12,507 so you got to be very careful with it. 520 00:18:12,592 --> 00:18:14,592 If I could just get this cap off! 521 00:18:14,677 --> 00:18:16,928 The super glue won't open. Well, the top's coming off. 522 00:18:17,013 --> 00:18:18,262 That's not good. 523 00:18:18,348 --> 00:18:19,764 Oh, way too much. Way too much. 524 00:18:19,808 --> 00:18:21,808 And boom, everywhere. It's on my hands. 525 00:18:21,893 --> 00:18:24,102 It's on the painter's tape. 526 00:18:24,145 --> 00:18:26,062 My pieces are glued together. [groans] 527 00:18:26,147 --> 00:18:27,980 I am extremely nervous at this point. 528 00:18:28,066 --> 00:18:29,482 What if I can't get these apart? 529 00:18:29,567 --> 00:18:31,067 If I can't get this handle material to work, 530 00:18:31,152 --> 00:18:32,610 I have no more options. 531 00:18:32,654 --> 00:18:33,903 I've come too far in this challenge, 532 00:18:33,988 --> 00:18:35,363 and the last thing I want to do is go home 533 00:18:35,448 --> 00:18:37,448 because I couldn't get a handle on this. 534 00:18:37,534 --> 00:18:38,866 Oh, god. 535 00:18:41,287 --> 00:18:42,578 ♪ ♪ - [groans] 536 00:18:42,664 --> 00:18:44,122 my pieces are glued together. I am extremely nervous. 537 00:18:44,165 --> 00:18:46,332 What if I can't get these apart? 538 00:18:46,417 --> 00:18:48,876 It's acrylic, so I have to be very, very careful. 539 00:18:48,962 --> 00:18:50,962 - My father would be so mad at him right now, 540 00:18:51,005 --> 00:18:52,213 saying something to the extent of, 541 00:18:52,298 --> 00:18:54,173 "a ruler is not a chisel. 542 00:18:54,259 --> 00:18:56,008 Get the right tool for the job, ben." 543 00:18:56,094 --> 00:18:57,969 - it's not working. My alternate thought is, 544 00:18:58,012 --> 00:18:59,387 "well, then you're gonna have to go grab the horn." 545 00:18:59,472 --> 00:19:01,264 I've never messed with that, 546 00:19:01,349 --> 00:19:04,225 and I don't want to try and push my luck today. 547 00:19:04,310 --> 00:19:07,395 Thank god it pops apart. Try that one more time. 548 00:19:07,480 --> 00:19:09,522 [rock music] 549 00:19:09,607 --> 00:19:10,815 - now that's better. 550 00:19:10,859 --> 00:19:12,692 I'm super happy with the shape of the knife. 551 00:19:12,777 --> 00:19:15,236 So I'm done with grinding. Okay. 552 00:19:15,321 --> 00:19:16,904 Get the epoxy resin and handles, 553 00:19:16,990 --> 00:19:19,532 and I'm free-handing the holes. 554 00:19:19,617 --> 00:19:20,741 First hole's perfect. 555 00:19:20,827 --> 00:19:22,201 I want to put in the second hole. 556 00:19:22,287 --> 00:19:24,120 It's too close to the edge. 557 00:19:24,205 --> 00:19:25,705 Oh, [bleep]. 558 00:19:25,790 --> 00:19:26,873 My handle cracked. 559 00:19:26,958 --> 00:19:29,083 Oh. My world collapses. 560 00:19:29,169 --> 00:19:31,377 I had to start all over. [grunts] 561 00:19:31,462 --> 00:19:33,629 I still have a bit of the micarta, 562 00:19:33,715 --> 00:19:35,715 but I've never worked with it before. 563 00:19:35,800 --> 00:19:37,550 ♪ ♪ 564 00:19:37,635 --> 00:19:39,302 yeah, man. And it works. 565 00:19:39,387 --> 00:19:40,428 Oh, my god. I'm so happy. 566 00:19:40,513 --> 00:19:41,512 [laughs] 567 00:19:41,556 --> 00:19:43,306 ♪ ♪ 568 00:19:43,391 --> 00:19:44,891 - I'm addressing my weight issue. 569 00:19:44,976 --> 00:19:48,060 I'm running fullers down the length of my blade. 570 00:19:48,146 --> 00:19:50,605 - That's smart because it reduces the weight 571 00:19:50,690 --> 00:19:52,315 coming out of the entire blade 572 00:19:52,400 --> 00:19:54,275 without really changing the strength. 573 00:19:54,360 --> 00:19:55,776 - Okay. Okay. 574 00:19:55,862 --> 00:19:58,321 I'm not worried about my handle material being perfect. 575 00:19:58,406 --> 00:19:59,864 I just need to get the holes in there. 576 00:19:59,908 --> 00:20:02,700 So the holes I'm just going to use 5.56 rounds 577 00:20:02,744 --> 00:20:04,118 as the pin stock. 578 00:20:04,204 --> 00:20:05,786 They're long enough to fit through my handle, 579 00:20:05,872 --> 00:20:06,996 and I know they're long enough 580 00:20:07,081 --> 00:20:08,497 to grab on to the handle material. 581 00:20:08,583 --> 00:20:10,041 - To do that right, 582 00:20:10,084 --> 00:20:11,667 you really don't want that whole casing sticking up. 583 00:20:11,753 --> 00:20:13,044 That's what we call a "hotspot." 584 00:20:13,129 --> 00:20:14,837 - good. - Yippy. 585 00:20:14,923 --> 00:20:16,631 Now that my handle's all clamped up, 586 00:20:16,716 --> 00:20:17,673 I figure it's good enough time for me 587 00:20:17,759 --> 00:20:19,884 to go over to the grinder. 588 00:20:19,928 --> 00:20:22,511 My edge is just about to the point where I want it to be. 589 00:20:22,597 --> 00:20:24,430 I start shaping my handle. 590 00:20:24,515 --> 00:20:26,224 If I were to win the $10,000, 591 00:20:26,267 --> 00:20:27,642 I'd give $2,000 to the church right away, 592 00:20:27,727 --> 00:20:30,561 but the other $5,000 or whatever the-- 593 00:20:30,605 --> 00:20:33,022 whatever how it goes, shakes out in the end, 594 00:20:33,107 --> 00:20:34,440 I'd probably just put it in the bank. 595 00:20:34,525 --> 00:20:37,568 I'm really not good at math. I told you that. [laughs] 596 00:20:37,654 --> 00:20:40,071 - it's all finished. It could not have been better. 597 00:20:40,114 --> 00:20:41,489 ♪ ♪ 598 00:20:41,574 --> 00:20:42,823 I'm done with the handle 599 00:20:42,909 --> 00:20:45,243 and try to make it as sharp as possible. 600 00:20:45,286 --> 00:20:49,121 Normally I like to sharpen my knives into the bathtub 601 00:20:49,207 --> 00:20:51,123 because after a long day of work, 602 00:20:51,209 --> 00:20:52,917 we're all black and dirty, 603 00:20:53,002 --> 00:20:55,711 so I sit in the bathtub with my sandpaper 604 00:20:55,755 --> 00:20:58,339 and finish up the knives that I make. 605 00:20:58,424 --> 00:21:01,884 My wife thinks I'm nuts, but I'm dutch is the thing. 606 00:21:01,970 --> 00:21:04,595 - Gentlemen, you've got five minutes remaining. 607 00:21:04,681 --> 00:21:07,306 - Running out of time. - So I'm feeling pretty good. 608 00:21:07,392 --> 00:21:09,892 I'm doing my rough shaping of my handle material. 609 00:21:09,936 --> 00:21:11,143 Okay. 610 00:21:11,229 --> 00:21:12,937 I've watched this competition enough times 611 00:21:12,981 --> 00:21:16,023 to see people go home for uncomfortable handles. 612 00:21:16,109 --> 00:21:18,818 It's something that you need to be thinking about. 613 00:21:18,903 --> 00:21:21,654 Winning this competition would change my knife-making career. 614 00:21:21,739 --> 00:21:23,948 I'd be able to step up to that next tier. 615 00:21:24,033 --> 00:21:26,951 It would definitely change the quality of my work. 616 00:21:27,036 --> 00:21:29,370 - Five. Four. 617 00:21:29,455 --> 00:21:31,789 Three. Two. One. 618 00:21:31,874 --> 00:21:34,083 Place your weapons down. Turn off your machines. 619 00:21:34,168 --> 00:21:35,876 This round is over. 620 00:21:35,962 --> 00:21:37,503 - I have faith in my skill. 621 00:21:37,588 --> 00:21:39,964 But having to put my blades through something like this, 622 00:21:40,008 --> 00:21:42,008 I want to see 'em use it. I want to see 'em break stuff. 623 00:21:42,093 --> 00:21:44,176 But I don't want to see them break my blade. 624 00:21:44,262 --> 00:21:45,636 - All right, gentlemen, I think you know what time it is. 625 00:21:45,680 --> 00:21:48,431 It's time for the strength test. 626 00:21:48,516 --> 00:21:49,807 Now, to test the strength 627 00:21:49,892 --> 00:21:51,475 and overall construction of your blades, 628 00:21:51,519 --> 00:21:53,811 I will be swinging into these ammo cans. 629 00:21:53,896 --> 00:21:56,105 Josh, you're up first. You ready? 630 00:21:56,149 --> 00:21:58,774 - Let's do it. 631 00:21:58,860 --> 00:22:00,526 I'm the first to go, and I see this 632 00:22:00,611 --> 00:22:02,320 big, old 40mm can, 633 00:22:02,363 --> 00:22:04,864 and my confidence slowly starts to dwindle. 634 00:22:04,949 --> 00:22:06,073 This is gonna be a lot more brutal 635 00:22:06,159 --> 00:22:07,825 than I thought it was gonna be. 636 00:22:07,869 --> 00:22:14,832 ♪ ♪ 637 00:22:19,005 --> 00:22:20,713 whew. [chuckles] 638 00:22:20,798 --> 00:22:22,757 ♪ ♪ 639 00:22:22,842 --> 00:22:24,550 - all right, josh, 640 00:22:24,635 --> 00:22:26,761 when I grab your handle right off, it's comfortable. 641 00:22:26,846 --> 00:22:30,306 Your use of the shells for the holes is great. 642 00:22:30,391 --> 00:22:32,641 It would've been nice to file the insides of them off. 643 00:22:32,685 --> 00:22:34,602 The weight of your knife, it's good. 644 00:22:34,687 --> 00:22:36,103 It feels pretty right. 645 00:22:36,189 --> 00:22:38,731 On your edge, you've got a couple spots up the tip 646 00:22:38,816 --> 00:22:40,399 that are more chips than rolls. 647 00:22:40,485 --> 00:22:42,360 And then down here you've got rolls. 648 00:22:42,445 --> 00:22:44,320 But good job. - Thank you. 649 00:22:44,405 --> 00:22:46,405 - All right, menno, you're up. You ready? 650 00:22:46,491 --> 00:22:49,075 - Cut it in half. - [laughs] I'll try. 651 00:22:49,160 --> 00:22:50,576 ♪ ♪ 652 00:22:50,661 --> 00:22:52,203 - I know these canisters because I have these canisters 653 00:22:52,246 --> 00:22:53,913 at home. I know how hard they are 654 00:22:53,998 --> 00:22:55,456 because they dropped on my foot one time. 655 00:22:55,541 --> 00:22:57,708 What will it do to my knife? I'm super scared. 656 00:22:57,752 --> 00:23:04,715 ♪ ♪ 657 00:23:10,890 --> 00:23:13,724 ♪ ♪ 658 00:23:13,810 --> 00:23:16,685 - all right, so, menno, I'm not a huge fan of finger grooves, 659 00:23:16,771 --> 00:23:19,188 but this is sized beautifully for my hand. 660 00:23:19,232 --> 00:23:21,732 As far as the blade goes, we have chips here 661 00:23:21,776 --> 00:23:24,568 as opposed to a roll where it's too soft, 662 00:23:24,612 --> 00:23:26,028 this is--it's just brittle. 663 00:23:26,114 --> 00:23:28,239 It leaves some question about the heat treat. 664 00:23:28,324 --> 00:23:30,991 You can see the grains are really big. 665 00:23:31,077 --> 00:23:33,577 I mean, it looks like more of a sand than that velvet 666 00:23:33,663 --> 00:23:35,955 you want to see, but all-in-all, good job. 667 00:23:36,040 --> 00:23:37,248 - Thank you. 668 00:23:37,333 --> 00:23:39,417 - All right, brad, you're up. You ready? 669 00:23:39,502 --> 00:23:40,668 - I'm glad I wore my brown pants. 670 00:23:40,753 --> 00:23:43,462 [laughter] 671 00:23:43,548 --> 00:23:45,047 ♪ ♪ 672 00:23:45,133 --> 00:23:46,549 my heart's beating out of my chest. 673 00:23:46,634 --> 00:23:48,050 Did I get the right edge on it? 674 00:23:48,136 --> 00:23:49,677 Is it gonna be strong enough? Is it gonna break? 675 00:23:49,762 --> 00:23:51,929 Did I do something wrong? My palms are really sweaty. 676 00:23:51,973 --> 00:23:55,141 I'm just hoping there's not mom's spaghetti. [laughs] 677 00:23:55,226 --> 00:24:02,189 ♪ ♪ 678 00:24:08,281 --> 00:24:09,989 ♪ ♪ 679 00:24:10,074 --> 00:24:12,324 - all right, brad, first off as far as your handle goes, 680 00:24:12,410 --> 00:24:14,285 pretty much right where I want it. 681 00:24:14,370 --> 00:24:16,036 Having that palm swell there, it sits in. 682 00:24:16,122 --> 00:24:17,329 It fits my hand really nicely. 683 00:24:17,415 --> 00:24:20,082 On the blade, you've got primarily rolls here. 684 00:24:20,168 --> 00:24:23,461 There's a couple of chips, but good feel. 685 00:24:23,546 --> 00:24:24,587 Well done. Good knife. 686 00:24:24,672 --> 00:24:25,963 - Thank you very much. I appreciate it. 687 00:24:26,007 --> 00:24:28,090 ♪ ♪ 688 00:24:28,176 --> 00:24:30,634 - all right, bladesmiths, this is the sharpness test, 689 00:24:30,678 --> 00:24:33,429 the military bed slice. 690 00:24:33,514 --> 00:24:35,139 To find out how sharp your edges are, 691 00:24:35,183 --> 00:24:37,349 I will take your knife and do some slices 692 00:24:37,435 --> 00:24:39,477 on this canvas military bed. 693 00:24:39,562 --> 00:24:41,103 Josh, you're up first. You ready for this? 694 00:24:41,147 --> 00:24:42,188 - Let's do it. 695 00:24:42,273 --> 00:24:49,236 ♪ ♪ 696 00:25:06,172 --> 00:25:09,465 ♪ ♪ 697 00:25:09,550 --> 00:25:11,842 - all right, josh, let's talk about your blade here. 698 00:25:11,928 --> 00:25:14,553 First up, when I grab onto your handle, 699 00:25:14,639 --> 00:25:17,223 there are no sharp edges at all. 700 00:25:17,308 --> 00:25:18,933 It's comfortable in my hand. 701 00:25:19,018 --> 00:25:22,478 Your edge, you have a really rolled spot over here 702 00:25:22,563 --> 00:25:24,772 that took some material with it, 703 00:25:24,857 --> 00:25:28,025 but the rest of the blade is very sharp. 704 00:25:28,069 --> 00:25:30,402 It will cut. - Thank you. 705 00:25:30,488 --> 00:25:31,612 - Menno, your turn. So you ready? 706 00:25:31,697 --> 00:25:33,155 - Yeah. 707 00:25:33,241 --> 00:25:34,698 After the strength test, 708 00:25:34,784 --> 00:25:36,617 I'm not that confident anymore. 709 00:25:36,702 --> 00:25:38,077 Right now my stomach is in my throat. 710 00:25:38,162 --> 00:25:39,620 I see that my knife is not destroyed, 711 00:25:39,705 --> 00:25:41,705 but it probably won't cut anymore. 712 00:25:41,791 --> 00:25:44,583 It's a nylon cut. I'm really scared of that. 713 00:25:44,669 --> 00:25:49,255 ♪ ♪ 714 00:25:49,340 --> 00:25:49,588 - menno, your turn. So you ready? 715 00:25:49,674 --> 00:25:50,631 - Yeah. 716 00:25:50,716 --> 00:25:52,383 After the ammo chop, 717 00:25:52,468 --> 00:25:54,218 I'm not that confident anymore, 718 00:25:54,303 --> 00:25:56,887 so right now my stomach is in my throat. 719 00:25:56,931 --> 00:26:03,894 ♪ ♪ 720 00:26:09,235 --> 00:26:12,069 ♪ ♪ 721 00:26:12,113 --> 00:26:14,613 - all right, menno, let's talk about your blade here. 722 00:26:14,699 --> 00:26:17,283 First up, it's a forward-heavy blade, 723 00:26:17,368 --> 00:26:19,660 but the construction that you have for the handle 724 00:26:19,745 --> 00:26:21,328 actually locks it in. 725 00:26:21,414 --> 00:26:23,038 I have a very good grip on this. 726 00:26:23,124 --> 00:26:25,207 Now let's talk about your edge. 727 00:26:25,251 --> 00:26:29,920 The areas where these chips actually hit the canvas, 728 00:26:29,964 --> 00:26:31,880 it ripped rather than cut, 729 00:26:31,966 --> 00:26:33,924 but the edges that did make contact 730 00:26:34,010 --> 00:26:35,843 that are sharp cut easily. 731 00:26:35,928 --> 00:26:38,137 Overall, sir, it'll cut. 732 00:26:38,222 --> 00:26:39,513 - Thank you. 733 00:26:39,599 --> 00:26:41,307 - All right, brad, your turn. You ready, sir? 734 00:26:41,392 --> 00:26:43,767 - Not as ready as you. - Let's do this. 735 00:26:44,937 --> 00:26:51,775 ♪ ♪ 736 00:26:57,825 --> 00:26:58,699 - [chuckles] 737 00:26:58,784 --> 00:27:01,285 ♪ ♪ 738 00:27:01,329 --> 00:27:03,537 - all right, brad, let's talk about your blade here. 739 00:27:03,623 --> 00:27:08,584 First up, it's light, but it's strong and it's easy to wield. 740 00:27:08,669 --> 00:27:12,421 Your edge here had some rolling earlier in the strength test, 741 00:27:12,465 --> 00:27:14,882 but the movement of this blade allows me to move it 742 00:27:14,967 --> 00:27:17,051 to where I can get the cuts in. 743 00:27:17,136 --> 00:27:19,928 Overall, sir, it'll cut. 744 00:27:20,014 --> 00:27:21,180 - Thank you. 745 00:27:21,265 --> 00:27:23,766 ♪ ♪ 746 00:27:23,851 --> 00:27:26,060 - gentlemen, we gave you a very hard task in mission: Zero, 747 00:27:26,145 --> 00:27:28,020 but you all proved your worth in the forge. 748 00:27:28,105 --> 00:27:29,855 Unfortunately, one of you will not be going forward 749 00:27:29,940 --> 00:27:31,398 into round three of the competition, 750 00:27:31,484 --> 00:27:33,067 and that bladesmith is... 751 00:27:33,152 --> 00:27:34,902 ♪ ♪ 752 00:27:34,987 --> 00:27:36,695 menno. 753 00:27:36,781 --> 00:27:38,113 Ben abbott will tell you why. 754 00:27:38,199 --> 00:27:40,324 - Well, menno, your blade took significant chipping 755 00:27:40,409 --> 00:27:43,285 in the strength test, exposing large, brittle grains. 756 00:27:43,371 --> 00:27:44,536 Those big chips 757 00:27:44,622 --> 00:27:46,789 also affected its ability in the cutting test, 758 00:27:46,874 --> 00:27:48,707 and it's for those reasons that we're letting you go. 759 00:27:48,793 --> 00:27:50,209 - Okay. Fair. - Menno, I want to say 760 00:27:50,294 --> 00:27:51,502 thank you for all your hard work, 761 00:27:51,587 --> 00:27:53,295 but at this time I'm gonna have to ask you 762 00:27:53,381 --> 00:27:54,880 to leave the forge floor. 763 00:27:54,965 --> 00:27:56,590 - Thank you so much. 764 00:27:56,676 --> 00:27:58,384 I did not expect that my blade would crack 765 00:27:58,469 --> 00:28:00,344 or that it was that brittle. 766 00:28:00,388 --> 00:28:01,929 I'm gonna go home. 767 00:28:02,014 --> 00:28:04,598 I'm gonna go sit in the bathtub with a knife 768 00:28:04,684 --> 00:28:06,141 and kiss the puppies, hug the wife. 769 00:28:06,227 --> 00:28:07,309 I'll keep on forging. 770 00:28:07,395 --> 00:28:08,560 That's not the end of the world. 771 00:28:08,646 --> 00:28:09,937 I loved doing this. 772 00:28:10,022 --> 00:28:13,232 ♪ ♪ 773 00:28:13,317 --> 00:28:15,442 - all right, guys, congratulations. 774 00:28:15,528 --> 00:28:17,695 You both made it to round three of the competition 775 00:28:17,780 --> 00:28:20,280 where we will send you to your home forges for four days 776 00:28:20,366 --> 00:28:23,450 to make this iconic weapon from u.S. Military history. 777 00:28:23,536 --> 00:28:25,077 And that weapon is... 778 00:28:25,162 --> 00:28:27,079 ♪ ♪ 779 00:28:27,164 --> 00:28:30,165 the springfield 1905 bayonet. 780 00:28:30,251 --> 00:28:32,960 We will be providing a springfield 1903 781 00:28:33,045 --> 00:28:35,629 replica rifle to you. 782 00:28:35,715 --> 00:28:38,257 Your bayonets must fit 783 00:28:38,342 --> 00:28:41,969 snugly and securely on your rifle. 784 00:28:42,054 --> 00:28:43,345 - [bleep]. 785 00:28:43,431 --> 00:28:45,264 - Developed in the early 1900s, 786 00:28:45,349 --> 00:28:48,058 the m1905 springfield bayonet 787 00:28:48,144 --> 00:28:51,270 was used by american infantry for nearly 70 years 788 00:28:51,355 --> 00:28:53,564 from world war I through the vietnam war. 789 00:28:53,607 --> 00:28:54,898 These versatile weapons were designed 790 00:28:54,984 --> 00:28:56,859 with a mechanical device in the pommel 791 00:28:56,944 --> 00:28:58,861 that attached securely to the rifle 792 00:28:58,946 --> 00:29:00,904 while also featuring a comfortable handle, 793 00:29:00,948 --> 00:29:04,032 making it a very effective weapon in hand-to-hand combat. 794 00:29:04,118 --> 00:29:06,785 Featuring a sharp single edge, a long fuller, 795 00:29:06,871 --> 00:29:09,163 and a false edge, this lightweight bayonet 796 00:29:09,248 --> 00:29:12,708 could quickly deliver stabs and slashes to an opponent. 797 00:29:12,793 --> 00:29:14,585 The bayonet is still used today 798 00:29:14,628 --> 00:29:16,170 during military ceremonies 799 00:29:16,255 --> 00:29:18,505 and can be seen in several classic war films 800 00:29:18,591 --> 00:29:21,091 like 1998's "the thin red line." 801 00:29:21,135 --> 00:29:22,176 - all right, gentlemen, 802 00:29:22,261 --> 00:29:23,343 when you guys build your bayonets, 803 00:29:23,429 --> 00:29:24,720 I want you to follow these parameters. 804 00:29:24,805 --> 00:29:27,598 Your blade needs to be between 15" and 16" 805 00:29:27,683 --> 00:29:30,225 with a fuller and a false edge at the tip 806 00:29:30,311 --> 00:29:32,644 as well as a muzzle ring guard. 807 00:29:32,730 --> 00:29:34,021 - I'm a little nervous with it. 808 00:29:34,106 --> 00:29:35,606 I've never done a guard on a knife before, 809 00:29:35,691 --> 00:29:37,816 let alone with a keyhole, and I know with the bayonets, 810 00:29:37,902 --> 00:29:39,902 they usually have a place in the back of the handle 811 00:29:39,987 --> 00:29:41,862 where it locks into the rifle. 812 00:29:41,947 --> 00:29:43,489 There's a lot of firsts. [laughs] 813 00:29:43,574 --> 00:29:44,782 - all right, gentlemen, good luck. 814 00:29:44,825 --> 00:29:46,325 We'll see you in four days. 815 00:29:46,410 --> 00:29:48,827 - Good luck, man. - Yeah. 816 00:29:48,913 --> 00:29:54,917 ♪ ♪ 817 00:29:54,960 --> 00:29:57,044 - it's beginning of day one. I'm a little nervous, 818 00:29:57,129 --> 00:29:58,712 but I'm ready to get in the forge and get to work. 819 00:29:58,798 --> 00:30:00,714 So for day one, my main plan 820 00:30:00,800 --> 00:30:02,341 is to get the whole blade forged out. 821 00:30:02,426 --> 00:30:04,426 I guess I could grind this to shape, 822 00:30:04,512 --> 00:30:06,220 but then it's not forged in fire. 823 00:30:06,305 --> 00:30:07,221 [laughs] 824 00:30:07,306 --> 00:30:11,683 ♪ ♪ 825 00:30:11,769 --> 00:30:12,976 so I'm forging out my blade, 826 00:30:13,062 --> 00:30:14,686 and this one's getting far too thin. 827 00:30:14,772 --> 00:30:16,647 And I'm really worried if they do any type of really 828 00:30:16,690 --> 00:30:19,233 strenuous durability tests, it won't hold up to it, 829 00:30:19,318 --> 00:30:21,360 so I'm just gonna scrap and start a new one. 830 00:30:21,445 --> 00:30:23,862 I'm starting a second piece. I have this one pretty much 831 00:30:23,948 --> 00:30:25,656 already drawn out to the right size. 832 00:30:25,699 --> 00:30:27,241 I just got to get to work again. 833 00:30:27,326 --> 00:30:31,495 ♪ ♪ 834 00:30:31,580 --> 00:30:32,871 this is my second attempt. 835 00:30:32,957 --> 00:30:34,790 Overall, I'm much more pleased with this one. 836 00:30:34,875 --> 00:30:36,083 I have everything forged out. 837 00:30:36,168 --> 00:30:38,126 Fuller's are in, rough dimensions are there. 838 00:30:38,212 --> 00:30:39,211 I'm happy. 839 00:30:39,296 --> 00:30:42,256 ♪ ♪ 840 00:30:42,341 --> 00:30:44,174 [bird caws] 841 00:30:44,260 --> 00:30:46,510 - so I'm back in lancaster, ohio at my home forge. 842 00:30:46,554 --> 00:30:48,136 I've never made anything this big before. 843 00:30:48,222 --> 00:30:50,264 The closest thing that I've come to of this size 844 00:30:50,349 --> 00:30:52,099 is what I did in round one. 845 00:30:52,184 --> 00:30:53,684 Starting to get there. 846 00:30:53,727 --> 00:30:58,355 ♪ ♪ 847 00:30:58,399 --> 00:31:00,649 all right, so I got the edges cleaned up fairly well. 848 00:31:00,693 --> 00:31:03,235 Overall my knife is pretty straight. 849 00:31:03,320 --> 00:31:06,488 It's got some little wobbles in there, but that's from forging. 850 00:31:06,574 --> 00:31:07,865 A little less than 1/8" 851 00:31:07,950 --> 00:31:10,576 to remove from this thing, and we're good. 852 00:31:10,661 --> 00:31:13,203 ♪ ♪ 853 00:31:13,247 --> 00:31:16,540 - so it's beginning of day two. Today I'm looking to assemble 854 00:31:16,625 --> 00:31:20,377 the butt pommel, ring attachment cap deal. 855 00:31:20,462 --> 00:31:21,503 [laughs] 856 00:31:21,547 --> 00:31:24,548 so right now I have my groove cut. 857 00:31:24,592 --> 00:31:28,760 These are gonna be the rest of my pommel. 858 00:31:28,846 --> 00:31:33,223 They are going to go like so and then be welded like that, 859 00:31:33,309 --> 00:31:36,351 so I have to use my angle grinder very, very, 860 00:31:36,437 --> 00:31:39,730 very carefully and scribe this line in 861 00:31:39,815 --> 00:31:42,357 thick enough that it fits on those rails. 862 00:31:42,443 --> 00:31:43,650 Line everything up. 863 00:31:43,736 --> 00:31:45,402 ♪ ♪ 864 00:31:45,487 --> 00:31:47,946 hey, hey, hey! It works. 865 00:31:48,032 --> 00:31:49,990 ♪ ♪ 866 00:31:50,075 --> 00:31:53,285 - so my plan for today is I'm going to quench my knife. 867 00:31:53,370 --> 00:31:55,162 I've never done a knife like this before. 868 00:31:55,247 --> 00:31:57,831 There's a lot of things that can go wrong in this process. 869 00:31:57,917 --> 00:31:59,541 Let's do this. 870 00:31:59,585 --> 00:32:01,877 I could have warping coming out of the quench. 871 00:32:01,962 --> 00:32:03,879 It could crack. 872 00:32:03,964 --> 00:32:07,299 So if this blade breaks, I'm screwed. 873 00:32:07,384 --> 00:32:11,261 ♪ ♪ 874 00:32:11,347 --> 00:32:12,888 - let's do this. 875 00:32:12,932 --> 00:32:16,934 I could have warping coming out of the quench. 876 00:32:16,977 --> 00:32:18,185 It could crack. 877 00:32:18,270 --> 00:32:20,729 So if this blade breaks, I'm screwed. 878 00:32:20,814 --> 00:32:24,483 ♪ ♪ 879 00:32:24,568 --> 00:32:27,194 so I'm not hearing any weird noises or any pings, 880 00:32:27,279 --> 00:32:29,279 so I think I'm in good shape. 881 00:32:29,323 --> 00:32:31,907 The biggest challenge of this build 882 00:32:31,992 --> 00:32:35,452 is getting that locking mechanism to work. 883 00:32:35,537 --> 00:32:37,955 I cut an l shorter, my bolster piece 884 00:32:37,998 --> 00:32:41,416 that would slide over the rail the bayonet attaches to. 885 00:32:41,502 --> 00:32:43,752 I'm gonna have to widen these a little bit more 886 00:32:43,837 --> 00:32:45,879 to fit around the thickness of that, 887 00:32:45,965 --> 00:32:48,548 which is something I can do fairly easily with a file. 888 00:32:48,634 --> 00:32:51,259 ♪ ♪ 889 00:32:51,345 --> 00:32:54,388 so now we're going to test with this. 890 00:32:54,473 --> 00:32:56,556 ♪ ♪ 891 00:32:56,642 --> 00:32:58,392 there she is. 892 00:32:58,477 --> 00:33:00,310 ♪ ♪ 893 00:33:00,354 --> 00:33:01,937 - beginning of day four. 894 00:33:01,981 --> 00:33:03,230 Today the process is gonna be 895 00:33:03,315 --> 00:33:04,481 a lot of cleaning up and grinding. 896 00:33:04,566 --> 00:33:07,693 I've got my scales all cut out. 897 00:33:07,778 --> 00:33:09,486 They fit relatively nice, 898 00:33:09,530 --> 00:33:11,405 and now I'm working on getting my pin, 899 00:33:11,490 --> 00:33:14,324 but that's gonna look pretty cool when it's done. 900 00:33:14,368 --> 00:33:15,993 I have my knife all glued up. 901 00:33:16,078 --> 00:33:18,120 Now that it's dry, I'm ready to take the clamps off 902 00:33:18,205 --> 00:33:21,248 and I'll start profiling the handle. 903 00:33:21,333 --> 00:33:22,666 At the end process, 904 00:33:22,710 --> 00:33:24,001 it's probably one of the best things I've made. 905 00:33:24,044 --> 00:33:26,336 I'm pretty proud of this. 906 00:33:26,380 --> 00:33:29,631 - It's the final day. Almost to the finish line. 907 00:33:29,717 --> 00:33:32,467 Yeah, let's do this. Say "hi." 908 00:33:32,553 --> 00:33:36,388 [laughs] you're so silly. 909 00:33:36,473 --> 00:33:37,806 Got the handle all glued up last night. 910 00:33:37,891 --> 00:33:39,099 I'm just gonna cut off all these pins 911 00:33:39,184 --> 00:33:40,726 and get a rough shape. 912 00:33:40,811 --> 00:33:43,770 Clean everything up. If I didn't know any better, 913 00:33:43,856 --> 00:33:45,605 and I found this sitting in my grandpa's attic, 914 00:33:45,691 --> 00:33:48,358 I'd think that this was from world war ii or something. 915 00:33:48,444 --> 00:33:51,028 I try to really pride myself on my fit and finish, 916 00:33:51,071 --> 00:33:52,988 and I'm pretty confident in my knife. 917 00:33:53,073 --> 00:33:54,614 I'm really happy with it. 918 00:33:54,700 --> 00:33:57,034 I wouldn't want to be on the other end of this thing. 919 00:33:57,077 --> 00:33:59,703 Let's see what it does. Yeah. 920 00:33:59,788 --> 00:34:02,456 This thing is sweet. Let's see. 921 00:34:02,541 --> 00:34:03,832 ♪ ♪ 922 00:34:03,876 --> 00:34:05,167 [laughs] 923 00:34:05,252 --> 00:34:07,002 ♪ ♪ 924 00:34:07,087 --> 00:34:09,337 this thing is sharp. 925 00:34:09,423 --> 00:34:11,048 Dude, that didn't even make any noise. 926 00:34:11,091 --> 00:34:12,674 It just stabbed right through it. 927 00:34:12,760 --> 00:34:18,513 ♪ ♪ 928 00:34:18,599 --> 00:34:20,515 - well, guys, welcome back to the forge. 929 00:34:20,601 --> 00:34:22,476 The two of you came out on top in mission: Zero, 930 00:34:22,561 --> 00:34:24,061 and we sent you home for four days 931 00:34:24,146 --> 00:34:26,980 to work on your renditions of the springfield bayonet. 932 00:34:27,066 --> 00:34:28,231 Now, we can only choose one of you 933 00:34:28,275 --> 00:34:29,816 to be the champion of "forged in fire" 934 00:34:29,902 --> 00:34:31,443 and go home with that $10,000, 935 00:34:31,528 --> 00:34:33,236 but first we absolutely want to hear about your builds 936 00:34:33,280 --> 00:34:35,238 and how they went. Josh, how'd it go? 937 00:34:35,324 --> 00:34:37,741 - It went pretty smoothly. 938 00:34:37,785 --> 00:34:39,743 It's made out of 1084. 939 00:34:39,787 --> 00:34:41,244 The handle is vintage micarta 940 00:34:41,288 --> 00:34:44,915 with high-carbon guard and pommel. 941 00:34:44,958 --> 00:34:45,874 - And brad, how'd it go for you? 942 00:34:45,918 --> 00:34:47,709 - It went pretty well. 943 00:34:47,795 --> 00:34:49,795 The blade is made out of 5160 leaf spring, 944 00:34:49,880 --> 00:34:52,881 and the handle is oak. 945 00:34:52,966 --> 00:34:54,007 - All right, guys, let's get into it. 946 00:34:54,093 --> 00:34:56,218 And up first, the keal test. Doug? 947 00:34:56,303 --> 00:34:59,429 ♪ ♪ 948 00:34:59,473 --> 00:35:02,265 - bladesmiths, welcome to the keal test. 949 00:35:02,309 --> 00:35:05,352 The first mission today is to take your bayonet 950 00:35:05,437 --> 00:35:07,062 and affix it to the springfield rifle 951 00:35:07,147 --> 00:35:10,565 and deliver some killing blows on this ballistics dummy. 952 00:35:10,651 --> 00:35:13,777 Then I will dismantle the blade from the rifle, 953 00:35:13,862 --> 00:35:14,736 and let's see what kind of lethal damage 954 00:35:14,780 --> 00:35:15,946 it will do on its own. 955 00:35:15,989 --> 00:35:17,656 Josh, you're up first. You ready? 956 00:35:17,741 --> 00:35:20,742 - As ready as I can be. - All right, let's do this. 957 00:35:20,828 --> 00:35:24,246 ♪ ♪ 958 00:35:24,289 --> 00:35:26,289 - my biggest concern is the back of the handle 959 00:35:26,333 --> 00:35:27,457 where it locks into the rifle. 960 00:35:27,543 --> 00:35:29,209 If it wants to move around or slide, 961 00:35:29,294 --> 00:35:31,253 it could, you know, break my handle, 962 00:35:31,338 --> 00:35:33,380 so that's really got me nervous right now. 963 00:35:33,465 --> 00:35:40,428 ♪ ♪ 964 00:35:49,314 --> 00:35:54,734 ♪ ♪ 965 00:35:54,820 --> 00:35:56,987 - [laughs] - that's pretty badass. 966 00:35:57,030 --> 00:35:58,947 - All right, josh, let's talk about your bayonet here. 967 00:35:59,032 --> 00:36:01,366 When I affixed this onto the rifle, 968 00:36:01,451 --> 00:36:04,411 it had a very nice match with the railing in there, 969 00:36:04,496 --> 00:36:06,413 and your pin, it was very secure. 970 00:36:06,498 --> 00:36:09,291 Now, your edge is very sharp. 971 00:36:09,376 --> 00:36:12,794 It definitely lacerates deep into the bone. 972 00:36:12,880 --> 00:36:15,005 On its own, the handle construction 973 00:36:15,090 --> 00:36:17,799 matches nicely on my hand. 974 00:36:17,885 --> 00:36:20,844 Overall, sir, it will keal. 975 00:36:20,888 --> 00:36:22,888 - Awesome. Thank you. - All right, brad, your turn. 976 00:36:22,973 --> 00:36:25,557 So you ready for this? - Let's go for it. 977 00:36:25,642 --> 00:36:27,601 I'm a little nervous because the last thing I want to do 978 00:36:27,686 --> 00:36:28,852 is have a blade that goes up 979 00:36:28,937 --> 00:36:30,812 and just whacks the dummy and bounces off. 980 00:36:30,898 --> 00:36:32,772 ♪ ♪ 981 00:36:32,858 --> 00:36:34,774 give him the old stab-and-poke. 982 00:36:34,860 --> 00:36:41,615 ♪ ♪ 983 00:36:48,957 --> 00:36:50,916 oof. 984 00:36:51,001 --> 00:36:53,877 - All right, brad, first up, the handle construction. 985 00:36:53,921 --> 00:36:56,296 It is a little bit on the smaller side, 986 00:36:56,381 --> 00:36:58,131 but there are no sharp edges, 987 00:36:58,217 --> 00:37:00,133 and the flare you have here aptly gives me good retention 988 00:37:00,219 --> 00:37:01,968 and I can get all the way to the guard. 989 00:37:02,054 --> 00:37:03,470 At first, I was a little bit worried 990 00:37:03,555 --> 00:37:04,804 about your cotter pin right here. 991 00:37:04,890 --> 00:37:06,264 It looked flimsy, 992 00:37:06,350 --> 00:37:08,975 but the minute I put it on, it wasn't an issue at all. 993 00:37:09,061 --> 00:37:11,311 It stayed affixed to the bayonet quite tightly. 994 00:37:11,396 --> 00:37:12,979 Your weapon is straight. 995 00:37:13,065 --> 00:37:16,816 Every cut was very deep into this ballistics dummy. 996 00:37:16,902 --> 00:37:19,027 Overall, sir, your weapon will keal. 997 00:37:19,112 --> 00:37:20,362 - Thank you, sir. 998 00:37:20,447 --> 00:37:22,989 ♪ ♪ 999 00:37:23,075 --> 00:37:24,908 - bladesmiths, welcome to the strength test, 1000 00:37:24,952 --> 00:37:28,036 the steel can stab and barricade chop. 1001 00:37:28,121 --> 00:37:30,038 This test is all about what happens to your bayonets 1002 00:37:30,123 --> 00:37:31,748 and not what happens to the targets. 1003 00:37:31,792 --> 00:37:32,958 Josh, you're up first. You ready? 1004 00:37:33,043 --> 00:37:35,085 - Nope. No. 1005 00:37:35,170 --> 00:37:37,295 [bleep]. [clears throat] 1006 00:37:37,381 --> 00:37:38,880 I see this steel drum sitting there. 1007 00:37:38,924 --> 00:37:41,424 Immediately my heart kind of hits my stomach. 1008 00:37:41,510 --> 00:37:44,010 It could roll my entire edge. My heat treat's off. 1009 00:37:44,096 --> 00:37:45,470 If I don't have an edge on my knife, 1010 00:37:45,555 --> 00:37:47,430 then in the sharpness test, it's not gonna perform, 1011 00:37:47,474 --> 00:37:49,724 so yeah, I'm a little nervous. [laughs] 1012 00:37:49,810 --> 00:37:52,686 or maybe not a little nervous. I'm a lot nervous. 1013 00:37:52,771 --> 00:37:56,147 ♪ ♪ 1014 00:37:56,233 --> 00:37:57,816 - I see this steel drum sitting there, 1015 00:37:57,943 --> 00:37:59,359 and my heart kind of hits my stomach. 1016 00:37:59,444 --> 00:38:02,570 It could roll my entire edge, so I'm a little nervous. 1017 00:38:02,656 --> 00:38:04,239 ♪ ♪ 1018 00:38:04,324 --> 00:38:09,369 ♪ ♪ 1019 00:38:09,454 --> 00:38:10,996 there goes my finish. 1020 00:38:11,081 --> 00:38:17,794 ♪ ♪ 1021 00:38:17,838 --> 00:38:19,879 whew. [bleep]. 1022 00:38:19,965 --> 00:38:22,007 - All right, josh. Well, you survived really well. 1023 00:38:22,092 --> 00:38:24,676 There is sections on here that are now 1024 00:38:24,761 --> 00:38:27,345 not as sharp as they were, but nothing rolled over. 1025 00:38:27,431 --> 00:38:28,680 Nothing chipped out. 1026 00:38:28,765 --> 00:38:30,765 Your point is still nice and sharp. 1027 00:38:30,851 --> 00:38:32,309 It performed really well on the strength test. 1028 00:38:32,352 --> 00:38:33,893 Nice job. - Awesome. Thank you. 1029 00:38:33,979 --> 00:38:35,562 - All right, brad. Are you ready for this? 1030 00:38:35,647 --> 00:38:37,314 - Well, my nan said don't break it, but go for it. 1031 00:38:37,399 --> 00:38:38,606 [laughs] 1032 00:38:38,692 --> 00:38:45,655 ♪ ♪ 1033 00:38:53,040 --> 00:38:55,123 - well, brad, what you got here, 1034 00:38:55,208 --> 00:38:57,500 your blade edge took some damage. 1035 00:38:57,586 --> 00:38:59,919 The blade's taken a bit of a bend to one side here. 1036 00:39:00,005 --> 00:39:01,212 It's cheating to the right, 1037 00:39:01,298 --> 00:39:03,173 but your point didn't take any damage. 1038 00:39:03,258 --> 00:39:05,717 It's all in one piece. It's a nice sturdy blade. 1039 00:39:05,802 --> 00:39:07,385 Nice job. - Thank you. 1040 00:39:07,471 --> 00:39:10,638 ♪ ♪ 1041 00:39:10,724 --> 00:39:13,141 - all right, bladesmiths, this is the sharpness test, 1042 00:39:13,226 --> 00:39:15,226 the military bag slice. 1043 00:39:15,312 --> 00:39:16,895 To find out how sharp your edges 1044 00:39:16,980 --> 00:39:18,271 and point of your bayonets are, 1045 00:39:18,357 --> 00:39:20,690 I'm gonna take a stab at these military bags. 1046 00:39:20,776 --> 00:39:22,025 Josh, you're up first. You ready? 1047 00:39:22,110 --> 00:39:23,568 - Let's go for it. 1048 00:39:23,653 --> 00:39:30,367 ♪ ♪ 1049 00:39:37,584 --> 00:39:39,876 - all right, josh, your bayonet right here 1050 00:39:39,961 --> 00:39:42,295 had no problems puncturing the bag 1051 00:39:42,381 --> 00:39:45,507 and slicing it to pieces. It'll cut. 1052 00:39:45,592 --> 00:39:47,467 - Sweet. Thanks. 1053 00:39:47,552 --> 00:39:48,760 - All right, brad, your turn, sir. 1054 00:39:48,845 --> 00:39:50,303 Shall we do it? - Of course. 1055 00:39:50,389 --> 00:39:51,513 Have at you. [laughs] 1056 00:39:51,598 --> 00:39:58,645 ♪ ♪ 1057 00:40:03,944 --> 00:40:05,860 - pew-pew-pew. [laughter] 1058 00:40:05,946 --> 00:40:07,862 ♪ ♪ 1059 00:40:07,906 --> 00:40:10,323 all right, brad, let's talk about your blade here. 1060 00:40:10,409 --> 00:40:11,616 Wicked sharp. 1061 00:40:11,701 --> 00:40:13,952 It punctured easily in the military bag, 1062 00:40:14,037 --> 00:40:18,248 at the same time the edges cut like hot steel on butter. 1063 00:40:18,291 --> 00:40:21,876 Overall, sir, for this test, it will cut. 1064 00:40:21,962 --> 00:40:23,461 - Thank you, sir. 1065 00:40:23,547 --> 00:40:30,427 ♪ ♪ 1066 00:40:30,512 --> 00:40:32,303 - gentlemen, both your blades performed extremely well, 1067 00:40:32,389 --> 00:40:34,139 and your bayonet's fitment was better 1068 00:40:34,224 --> 00:40:36,182 than anything I've seen, and I've used quite a few, 1069 00:40:36,268 --> 00:40:38,101 but it is time for the judges to make a decision. 1070 00:40:38,186 --> 00:40:39,477 For that I'm gonna ask you to please 1071 00:40:39,563 --> 00:40:40,895 step off the forge floor. 1072 00:40:40,981 --> 00:40:46,609 ♪ ♪ 1073 00:40:46,695 --> 00:40:48,862 - all right, guys, we've got to make a decision. 1074 00:40:48,947 --> 00:40:49,988 So, dave, what'd you see? 1075 00:40:50,073 --> 00:40:51,781 - It's a difficult challenge because 1076 00:40:51,867 --> 00:40:53,825 it's a mechanical challenge as well as building a weapon. 1077 00:40:53,910 --> 00:40:56,119 Brad's blade had that cotter pin, 1078 00:40:56,204 --> 00:40:58,121 which I thought was a better connection. 1079 00:40:58,165 --> 00:40:59,956 But at the same time, it's a pretty weak connection. 1080 00:41:00,041 --> 00:41:01,291 - Ben, how 'bout you? What'd you think? 1081 00:41:01,376 --> 00:41:03,168 - Brad's bayonet, the first thing I notice 1082 00:41:03,253 --> 00:41:05,170 when I pick it up is the handle is small. 1083 00:41:05,255 --> 00:41:06,671 It really did affect how I felt 1084 00:41:06,756 --> 00:41:08,965 when I was holding onto it in the strength test. 1085 00:41:09,009 --> 00:41:10,216 - Doug, what do you think? 1086 00:41:10,302 --> 00:41:12,844 - Both blades performed very well, 1087 00:41:12,929 --> 00:41:15,889 but one blade took a bend on it. 1088 00:41:15,974 --> 00:41:18,975 It was noticeable the minute I put it on the bayonet. 1089 00:41:19,060 --> 00:41:21,269 Whereas the other knife, I really like the profile. 1090 00:41:21,354 --> 00:41:23,646 It has almost a right scale and dimensions. 1091 00:41:23,732 --> 00:41:25,815 - Okay, so it sounds like you're all in agreement? 1092 00:41:25,901 --> 00:41:28,485 - Mm-hmm. - Okay, we'll call 'em in. 1093 00:41:28,570 --> 00:41:29,819 All right, gentlemen, 1094 00:41:29,905 --> 00:41:32,113 while you both brought us amazing work, 1095 00:41:32,199 --> 00:41:34,699 only one of you will go home with the title. 1096 00:41:34,784 --> 00:41:37,118 And the "forged in fire" champion is... 1097 00:41:37,204 --> 00:41:40,747 ♪ ♪ 1098 00:41:40,832 --> 00:41:41,831 josh. 1099 00:41:41,917 --> 00:41:43,625 - Holy [bleep]. - Congratulations. 1100 00:41:43,710 --> 00:41:45,335 - [laughs] - brad, unfortunately, 1101 00:41:45,420 --> 00:41:46,878 you're not going home with the win today, 1102 00:41:46,963 --> 00:41:48,087 and doug's gonna tell you why. 1103 00:41:48,173 --> 00:41:49,339 - I commend you on your work. 1104 00:41:49,424 --> 00:41:51,424 Your knife performed very well on our test, 1105 00:41:51,510 --> 00:41:52,759 but it was also the only knife 1106 00:41:52,844 --> 00:41:54,344 that took a bend on the strength test. 1107 00:41:54,429 --> 00:41:57,263 And for that reason, your blade did not make the cut. 1108 00:41:57,349 --> 00:41:58,640 - Brad, unfortunately that means I'm gonna have to ask you 1109 00:41:58,725 --> 00:42:00,016 to please leave the forge floor. 1110 00:42:00,101 --> 00:42:01,893 - I understand. Have a good one, guys. 1111 00:42:01,978 --> 00:42:03,686 - Pleasure, man. - Thank you. 1112 00:42:03,772 --> 00:42:05,813 When it comes to the judges' final decision, 1113 00:42:05,899 --> 00:42:08,608 I can't argue with it at all. I'm extremely proud of my work. 1114 00:42:08,693 --> 00:42:09,901 That was probably the best blade 1115 00:42:09,986 --> 00:42:11,402 I've ever made so far. 1116 00:42:11,488 --> 00:42:13,196 This has just been a dream come true, 1117 00:42:13,281 --> 00:42:15,198 and I'm just so grateful to be where I am right now 1118 00:42:15,242 --> 00:42:16,950 even if I am going home. 1119 00:42:17,035 --> 00:42:18,117 - Well, josh, that means 1120 00:42:18,203 --> 00:42:19,410 you are the "forged in fire" champion, 1121 00:42:19,496 --> 00:42:21,538 and you're going home with a check for $10,000. 1122 00:42:21,623 --> 00:42:23,540 How does it feel, bud? - I feel awesome. 1123 00:42:23,625 --> 00:42:24,958 - Congratulations. 1124 00:42:25,043 --> 00:42:27,460 [applause] 1125 00:42:27,546 --> 00:42:29,504 - I don't even know, man. [laughs] 1126 00:42:29,589 --> 00:42:32,131 I'm still trying to sink in that I won this--I won. 1127 00:42:32,217 --> 00:42:34,467 It's a little overwhelming. I can't wait to tell my wife. 1128 00:42:34,553 --> 00:42:36,928 She had a lot of confidence in me from the very start. 1129 00:42:37,013 --> 00:42:38,263 I'm excited to let her know that, 1130 00:42:38,348 --> 00:42:40,265 "hey, you were right, you know? I won." 1131 00:42:40,350 --> 00:42:46,729 ♪ ♪