1 00:00:05,006 --> 00:00:06,630 [dramatic music] 2 00:00:06,716 --> 00:00:08,007 - we've seen the best bladesmiths 3 00:00:08,092 --> 00:00:10,592 head back to their home forges to recreate 4 00:00:10,678 --> 00:00:11,969 some of the deadliest 5 00:00:12,054 --> 00:00:14,138 and most iconic weapons in history, 6 00:00:14,223 --> 00:00:15,723 and now it's our turn. 7 00:00:15,808 --> 00:00:17,474 ♪ ♪ 8 00:00:17,560 --> 00:00:19,685 each of us will battle it out in our own home shops 9 00:00:19,729 --> 00:00:21,603 in an intricate, two-week build... 10 00:00:21,689 --> 00:00:22,980 - [laughs] oh, no. 11 00:00:23,065 --> 00:00:24,606 In two weeks, make a sutton hoo sword. 12 00:00:24,692 --> 00:00:25,983 - Yeah, I know. 13 00:00:26,068 --> 00:00:27,526 Before passing on the torch to the next. 14 00:00:27,570 --> 00:00:29,862 - Mr. Baker, I got a challenge for you, bud. 15 00:00:29,947 --> 00:00:31,155 - Oh. 16 00:00:31,240 --> 00:00:33,699 Frustrating like I cannot tell you. 17 00:00:33,784 --> 00:00:35,659 With no outside help, we must rely 18 00:00:35,745 --> 00:00:38,120 on our own knowledge, equipment, 19 00:00:38,205 --> 00:00:39,371 and even camera skills. 20 00:00:39,457 --> 00:00:40,998 Whoa. 21 00:00:41,083 --> 00:00:42,416 - Where's your microphone? 22 00:00:42,501 --> 00:00:45,169 - Ah [bleep]. 23 00:00:46,213 --> 00:00:49,673 - This is the judges home forge battle. 24 00:00:49,759 --> 00:00:55,054 ♪ ♪ 25 00:00:55,139 --> 00:00:58,432 [country rock music] 26 00:00:58,517 --> 00:01:03,979 ♪ ♪ 27 00:01:04,065 --> 00:01:07,024 - hey, ben, j. How you guys doing? 28 00:01:07,109 --> 00:01:08,609 - Hey, dave, what you doing, man? 29 00:01:08,694 --> 00:01:09,860 - Hey, guys, what's up? 30 00:01:09,945 --> 00:01:11,445 - I'm down here at my new place in virginia, 31 00:01:11,530 --> 00:01:13,530 and I'm still kind of building the shop, 32 00:01:13,616 --> 00:01:15,616 but, well, I was thinking, you know, we've got 33 00:01:15,701 --> 00:01:18,077 this down time between shooting the show. 34 00:01:18,162 --> 00:01:19,536 It might be fun to do a little challenge 35 00:01:19,622 --> 00:01:20,954 among the three of us. 36 00:01:21,040 --> 00:01:22,623 - Me challenge ben, ben challenge j., 37 00:01:22,708 --> 00:01:24,416 j. Challenge me-- something like that? 38 00:01:24,502 --> 00:01:25,667 - So one person finishes 39 00:01:25,753 --> 00:01:27,419 and then challenges the next one. 40 00:01:27,505 --> 00:01:28,879 Sounds good to me. 41 00:01:28,964 --> 00:01:31,673 - So what I thought was that we'll do a home build. 42 00:01:31,759 --> 00:01:33,258 You know, we're always making the smiths do this, 43 00:01:33,302 --> 00:01:37,137 so I figure let's do one. Let's show off what we can do. 44 00:01:37,223 --> 00:01:38,639 - See if I can remember how. 45 00:01:38,724 --> 00:01:40,849 - [laughs] get all the rust off my anvil. 46 00:01:40,935 --> 00:01:42,351 - [laughs] so, no. 47 00:01:42,436 --> 00:01:43,477 Well, what I was thinking, 48 00:01:43,562 --> 00:01:44,728 we'd do it a little bit differently. 49 00:01:44,814 --> 00:01:46,063 We'll give each other two weeks 50 00:01:46,148 --> 00:01:47,481 to complete the challenge. 51 00:01:47,566 --> 00:01:49,858 I know that's longer than we usually give the smiths, 52 00:01:49,944 --> 00:01:52,069 but I figure let's do something 53 00:01:52,154 --> 00:01:54,154 kind of outside our normal comfort zone, 54 00:01:54,240 --> 00:01:55,155 do something, you know, 55 00:01:55,241 --> 00:01:56,740 a little bit more above and beyond. 56 00:01:56,826 --> 00:01:58,617 - All right. - Works for me. 57 00:01:58,702 --> 00:02:00,953 - Okay, ben, you're always talking 58 00:02:00,996 --> 00:02:02,412 about the sutton hoo sword. 59 00:02:02,498 --> 00:02:04,123 You even told me that you saw it in a museum in England? 60 00:02:04,208 --> 00:02:05,749 - Absolutely, yeah. 61 00:02:05,835 --> 00:02:08,418 - Look, I know it's an incredibly intricate sword, 62 00:02:08,504 --> 00:02:10,254 but you're always saying how you wanted to do one, 63 00:02:10,297 --> 00:02:11,630 and now's the perfect chance. 64 00:02:11,715 --> 00:02:12,923 - [laughs] oh, no. 65 00:02:13,008 --> 00:02:14,716 In two weeks, make a sutton hoo sword. 66 00:02:14,802 --> 00:02:16,260 - Yeah, I know. [chuckles] 67 00:02:16,345 --> 00:02:17,594 - ben's gonna be switching over to night shift 68 00:02:17,680 --> 00:02:19,638 for a couple weeks. - Yeah, thanks a lot, dave. 69 00:02:19,682 --> 00:02:21,640 - Found in the burial ground of sutton hoo 70 00:02:21,684 --> 00:02:23,142 in modern day suffolk, England, 71 00:02:23,227 --> 00:02:26,103 the sword was presumably wielded by king raedwald 72 00:02:26,188 --> 00:02:27,980 in the early 7th century. 73 00:02:28,023 --> 00:02:29,898 The blade features intricate-made 74 00:02:29,984 --> 00:02:31,024 pattern welding, 75 00:02:31,110 --> 00:02:32,359 twisting steel and wrought iron 76 00:02:32,444 --> 00:02:34,444 to create a unique damascus pattern, 77 00:02:34,530 --> 00:02:36,488 while the handle itself was just as elaborate, 78 00:02:36,574 --> 00:02:38,740 and was inlaid with gold and garnet. 79 00:02:38,826 --> 00:02:41,201 Over 1,300 years later, 80 00:02:41,287 --> 00:02:43,162 the sword was painstakingly recreated 81 00:02:43,205 --> 00:02:45,497 by scott langton, and is now on display 82 00:02:45,541 --> 00:02:48,667 alongside the original in the british museum. 83 00:02:48,752 --> 00:02:51,086 Look, you're always saying how much you love that sword. 84 00:02:51,172 --> 00:02:53,839 But hey, it's gonna be fun, and we gotta test 'em, 85 00:02:53,883 --> 00:02:57,342 so, ben, figure out how you're gonna test that sword, 86 00:02:57,428 --> 00:02:59,178 what you wanna test it on, okay? 87 00:02:59,263 --> 00:03:01,221 - Sounds good. - One more thing, guys. 88 00:03:01,307 --> 00:03:04,141 It's just us. Let's shoot ourselves. 89 00:03:04,226 --> 00:03:06,310 Ben, sorry to dig you such a deep hole, 90 00:03:06,395 --> 00:03:07,978 but have fun, man. 91 00:03:08,063 --> 00:03:09,354 I'll see you in two weeks, okay? 92 00:03:09,398 --> 00:03:10,272 Two weeks. 93 00:03:10,357 --> 00:03:11,815 - I think I'm gonna mutter 94 00:03:11,901 --> 00:03:13,400 about you a lot in the next two weeks, 95 00:03:13,485 --> 00:03:15,777 but thanks, I better get to work. 96 00:03:15,863 --> 00:03:18,822 [dramatic rock music] 97 00:03:18,908 --> 00:03:20,949 ♪ ♪ 98 00:03:21,035 --> 00:03:23,076 I'm not sure what's gonna be more difficult-- 99 00:03:23,162 --> 00:03:24,786 making a sutton hoo sword 100 00:03:24,872 --> 00:03:27,664 or being a cameraman and an audio man. 101 00:03:27,750 --> 00:03:30,250 This is all me, so please excuse it... 102 00:03:30,336 --> 00:03:32,002 [chuckles] if the shots aren't great, 103 00:03:32,087 --> 00:03:34,880 and I hope I make a cool sword at the other end of this. 104 00:03:34,965 --> 00:03:36,673 All right, here we go. 105 00:03:36,759 --> 00:03:39,676 Leave it up to dave, our historical weapons expert, 106 00:03:39,762 --> 00:03:42,387 to give me an extremely historical weapon to create. 107 00:03:42,473 --> 00:03:44,681 A sutton hoo sword replica-- 108 00:03:44,767 --> 00:03:47,851 I've wanted to make this sword since I was a little kid 109 00:03:47,937 --> 00:03:50,270 and went to the british museum and saw the reproduction, 110 00:03:50,356 --> 00:03:51,855 and I was really excited 111 00:03:51,941 --> 00:03:54,358 by this very elaborate pattern-welded blade. 112 00:03:54,443 --> 00:03:57,402 So now I'm in competition just with myself. 113 00:03:57,446 --> 00:03:58,695 Can I make the sword 114 00:03:58,781 --> 00:04:00,072 that I've always thought I could make? 115 00:04:00,157 --> 00:04:02,866 In this build, my reputation is on the line-- 116 00:04:02,952 --> 00:04:05,452 not globally, but within the three of us, 117 00:04:05,537 --> 00:04:07,537 so I wanna make sure I impress everybody. 118 00:04:07,623 --> 00:04:10,457 I'm gonna start by making my eight bars, 119 00:04:10,542 --> 00:04:12,376 which is gonna be high-layer damascus, 120 00:04:12,461 --> 00:04:14,461 and then I'll draw those out into these rods. 121 00:04:14,546 --> 00:04:16,171 Then I'm gonna twist and stop twisting 122 00:04:16,257 --> 00:04:17,714 and twist it and stop twisting. 123 00:04:17,800 --> 00:04:20,050 Then comes the forge welding-- four together this way, 124 00:04:20,135 --> 00:04:21,426 the other four together this way, 125 00:04:21,512 --> 00:04:23,387 except the top, where they're twisted, 126 00:04:23,472 --> 00:04:24,888 the bottoms are straight. 127 00:04:24,974 --> 00:04:27,557 Then weld those layers together for the twisted core. 128 00:04:27,643 --> 00:04:30,102 Then make the edge steel by making extra stock, 129 00:04:30,187 --> 00:04:32,354 throw it out, and wrap that all the way around the end 130 00:04:32,439 --> 00:04:34,564 and then forge weld that whole thing together. 131 00:04:34,650 --> 00:04:36,275 ♪ ♪ 132 00:04:36,360 --> 00:04:38,485 the two times I had to compete on this show, 133 00:04:38,570 --> 00:04:40,612 I made a khanda and a claymore, 134 00:04:40,698 --> 00:04:43,323 but this build is way more complex. 135 00:04:43,409 --> 00:04:44,574 54. 136 00:04:44,660 --> 00:04:46,159 There is no way that we could have 137 00:04:46,245 --> 00:04:48,161 the smiths on "forged in fire" make one of these swords. 138 00:04:48,247 --> 00:04:49,579 It's just too many steps, 139 00:04:49,665 --> 00:04:51,123 and there's too much time involved. 140 00:04:51,208 --> 00:04:52,624 I'm gonna stack them all up 141 00:04:52,710 --> 00:04:54,584 and try to get the initial forge weld. 142 00:04:54,670 --> 00:04:57,296 If the initial weld isn't tight, 143 00:04:57,381 --> 00:04:59,006 then, as I'm drawing out these billets, 144 00:04:59,091 --> 00:05:00,507 they can just come apart. 145 00:05:00,592 --> 00:05:02,759 If I mess up one billet, 146 00:05:02,845 --> 00:05:04,636 I have to start that billet all over again, 147 00:05:04,680 --> 00:05:07,639 and that would compromise the entire sword. 148 00:05:07,683 --> 00:05:10,892 Now we just continue going. Got seven more to do. 149 00:05:10,978 --> 00:05:13,228 [machine pops loudly] 150 00:05:14,148 --> 00:05:15,897 today's the beginning of day two. 151 00:05:15,983 --> 00:05:17,399 Here's the edge billet. 152 00:05:17,484 --> 00:05:21,570 It's about to go into the forge, 153 00:05:21,655 --> 00:05:23,196 do the first weld on it. 154 00:05:23,282 --> 00:05:25,032 ♪ ♪ 155 00:05:25,117 --> 00:05:27,743 the sword blade is about 28 inches long, 156 00:05:27,828 --> 00:05:30,454 so that's about 5 1/2 feet 157 00:05:30,539 --> 00:05:32,998 of bar I have to make in order to wrap it around. 158 00:05:33,083 --> 00:05:37,002 Once I get the edge bar welded and drawn out, 159 00:05:37,046 --> 00:05:39,296 I set it aside and put all my attention 160 00:05:39,381 --> 00:05:42,049 to the twists on the core bars. 161 00:05:42,134 --> 00:05:44,718 The steps of this process takes a little while, 162 00:05:44,803 --> 00:05:47,346 and then you have to multiply each of those steps by eight. 163 00:05:47,431 --> 00:05:50,140 I've done quite a bit of twisted damascus, 164 00:05:50,225 --> 00:05:52,017 but the precision in this build 165 00:05:52,102 --> 00:05:53,810 is its own trouble. 166 00:05:53,896 --> 00:05:55,520 If I'm too aggressive with the twisting, 167 00:05:55,606 --> 00:05:59,149 you can actually shear that bar into two bars. 168 00:05:59,234 --> 00:06:00,233 It's getting really late. 169 00:06:00,319 --> 00:06:01,860 It's about 2:00 in the morning, 170 00:06:01,945 --> 00:06:04,404 and I'm tired. I'm ready to go to sleep. 171 00:06:04,490 --> 00:06:07,157 ♪ ♪ 172 00:06:07,242 --> 00:06:10,202 yesterday, I got the last four bars twisted. 173 00:06:10,287 --> 00:06:12,829 Also the forge welding on the edge went really well. 174 00:06:12,915 --> 00:06:15,374 So now I've got quite a number of layers. 175 00:06:15,459 --> 00:06:17,542 Hopefully these days keep going as planned, 176 00:06:17,628 --> 00:06:20,837 and also hopefully my plan is a good one. 177 00:06:20,923 --> 00:06:23,048 Today is a pretty crucial day. 178 00:06:23,092 --> 00:06:25,759 I now have eight twisted and flattened bars. 179 00:06:25,844 --> 00:06:28,011 I have to weld the top four together, 180 00:06:28,097 --> 00:06:29,721 weld the bottom four together, 181 00:06:29,807 --> 00:06:32,599 weld those together making now the full core. 182 00:06:32,684 --> 00:06:35,519 Well, this is by far gonna be the most difficult day 183 00:06:35,562 --> 00:06:38,397 of forge welding of my career. 184 00:06:38,482 --> 00:06:41,358 Each of these bars is almost 30 inches long, 185 00:06:41,443 --> 00:06:43,318 so that's a lot of surface area to mess up. 186 00:06:43,404 --> 00:06:45,487 Any small failure in these welds 187 00:06:45,572 --> 00:06:46,863 could be catastrophic. 188 00:06:46,949 --> 00:06:48,031 Far as I can tell, 189 00:06:48,117 --> 00:06:50,200 everything looks good at the moment. 190 00:06:50,285 --> 00:06:51,827 The welding on the second billet 191 00:06:51,912 --> 00:06:53,203 is going great. 192 00:06:53,247 --> 00:06:54,746 I have about the last 8 inches of bar 193 00:06:54,832 --> 00:06:58,208 in the forge, so I can weld that last, little section. 194 00:06:58,293 --> 00:07:00,252 [machinery whooshes] 195 00:07:02,297 --> 00:07:03,880 my propane tank freezes up. 196 00:07:03,966 --> 00:07:07,134 Hot oxygen is getting blown onto the billet 197 00:07:07,219 --> 00:07:09,386 with no propane, so I'm really nervous 198 00:07:09,430 --> 00:07:10,554 that's gonna oxidize my billet 199 00:07:10,639 --> 00:07:11,721 and cause the forge weld not to stick. 200 00:07:11,807 --> 00:07:14,015 I need to swap tanks immediately, 201 00:07:14,101 --> 00:07:15,892 or else I could lose this entire weld. 202 00:07:15,978 --> 00:07:20,313 ♪ ♪ 203 00:07:20,399 --> 00:07:22,441 luckily, I was able to save the billet. 204 00:07:22,484 --> 00:07:23,692 All right. 205 00:07:23,777 --> 00:07:25,110 The welds look clean and tight, 206 00:07:25,195 --> 00:07:27,028 and everything seems to have welded up just fine. 207 00:07:27,114 --> 00:07:28,697 Problem averted. 208 00:07:28,782 --> 00:07:31,867 Tomorrow is gonna be welding those two packets together 209 00:07:31,952 --> 00:07:33,743 and welding the edge on. 210 00:07:33,829 --> 00:07:35,954 ♪ ♪ 211 00:07:36,039 --> 00:07:37,164 here we go. 212 00:07:37,249 --> 00:07:38,748 Today is the day where I can get 213 00:07:38,834 --> 00:07:40,917 this whole sword assembled. 214 00:07:41,003 --> 00:07:43,795 The forge welding of the two twisted billets 215 00:07:43,881 --> 00:07:45,505 went really well. 216 00:07:45,591 --> 00:07:48,133 The next step is to draw 'em out to the length I need. 217 00:07:48,177 --> 00:07:50,010 I don't really wanna go to the power hammer. 218 00:07:50,095 --> 00:07:51,928 I'm afraid of it just getting away from me, 219 00:07:52,014 --> 00:07:53,638 so I'm just gonna hand hammer it over the horn. 220 00:07:53,724 --> 00:07:56,141 After a couple of heats of widening this billet 221 00:07:56,185 --> 00:07:57,434 with a hand hammer, 222 00:07:57,478 --> 00:07:58,935 I'm starting to get really tired, 223 00:07:58,979 --> 00:08:00,687 so I think I'm gonna shift over 224 00:08:00,772 --> 00:08:02,272 and use the power hammer. 225 00:08:02,357 --> 00:08:04,441 ♪ ♪ 226 00:08:04,485 --> 00:08:06,818 oh, no, this is way too long. 227 00:08:08,155 --> 00:08:09,446 [bleep] 228 00:08:09,531 --> 00:08:11,364 now I've got a sword that's 6 inches too long. 229 00:08:11,450 --> 00:08:12,741 [bleep] 230 00:08:12,826 --> 00:08:13,867 I don't know how this happened. 231 00:08:13,952 --> 00:08:14,826 I was really methodical. 232 00:08:14,870 --> 00:08:16,369 [bleep] damn it. 233 00:08:16,455 --> 00:08:18,038 I guess it's just the stress of the time crunch. 234 00:08:18,123 --> 00:08:19,289 ♪ ♪ 235 00:08:19,374 --> 00:08:20,916 I'm gonna attempt to shorten the sword 236 00:08:21,001 --> 00:08:22,417 by a process called upsetting. 237 00:08:22,503 --> 00:08:23,835 I'm actually gonna do 238 00:08:23,921 --> 00:08:25,420 what you would imagine in a cartoon would do. 239 00:08:25,506 --> 00:08:28,215 I'm going to heat up a section, and I'm gonna hit the tang 240 00:08:28,300 --> 00:08:31,927 down to the point and try to smush the steel. 241 00:08:32,012 --> 00:08:35,680 The problem is, I run the risk of splitting these bars open 242 00:08:35,724 --> 00:08:38,767 by squeezing the steel down on itself. 243 00:08:38,852 --> 00:08:40,810 If what I do goes badly, 244 00:08:40,896 --> 00:08:42,312 I have to start it all over again. 245 00:08:42,397 --> 00:08:45,815 ♪ ♪ 246 00:08:45,901 --> 00:08:47,150 pushing this blade 247 00:08:47,236 --> 00:08:48,485 and putting your weight into it is like-- 248 00:08:48,570 --> 00:08:51,154 imagine playing jenga on the subway. 249 00:08:51,240 --> 00:08:53,657 If I snap my blade in half right now, I'd be devastated. 250 00:08:53,742 --> 00:08:55,325 ♪ ♪ 251 00:08:55,410 --> 00:08:57,619 - if this blade warps, I'm gonna be seriously pissed, 252 00:08:57,704 --> 00:08:58,745 and we might have to get 253 00:08:58,789 --> 00:09:00,330 the censor bleeping guys on here again. 254 00:09:00,415 --> 00:09:01,665 [bleep] 255 00:09:01,750 --> 00:09:04,125 ♪ ♪ 256 00:09:08,715 --> 00:09:11,299 - in trying to widen out twisted rods, 257 00:09:11,385 --> 00:09:14,052 the power hammer ended up drawing the sword out 258 00:09:14,137 --> 00:09:16,137 in length much more than I was hoping. 259 00:09:16,223 --> 00:09:17,556 [bleep]. 260 00:09:17,599 --> 00:09:21,893 So the plan is to shorten the sword by upsetting. 261 00:09:21,979 --> 00:09:26,147 If what I do goes badly, I can split open the pattern. 262 00:09:26,233 --> 00:09:29,901 ♪ ♪ 263 00:09:29,945 --> 00:09:31,403 it might. 264 00:09:31,488 --> 00:09:33,071 I've got big hope it's not bad. 265 00:09:33,156 --> 00:09:34,739 After a couple of passes of upsetting, 266 00:09:34,783 --> 00:09:37,867 I lie the blade onto the floor and check its length. 267 00:09:37,953 --> 00:09:40,245 So this is the line where we started, 268 00:09:40,289 --> 00:09:42,414 and this is the line where I'm gonna be finished, 269 00:09:42,457 --> 00:09:44,541 and you can see about an inch already. 270 00:09:44,626 --> 00:09:47,627 I feel really satisfied that I was able to imagine 271 00:09:47,713 --> 00:09:50,422 a solution to this problem without ever having done 272 00:09:50,465 --> 00:09:52,090 something like this before. 273 00:09:52,134 --> 00:09:53,425 That's how long it was when I started. 274 00:09:53,510 --> 00:09:55,760 Let's see where we ended up. 275 00:09:55,804 --> 00:09:58,013 Dang, son, that's looking pretty good. 276 00:09:58,098 --> 00:09:59,764 [laughs] 277 00:09:59,850 --> 00:10:04,019 what I need to do today is reduce its weight. 278 00:10:04,104 --> 00:10:06,438 We're gonna see if I can reduce its weight 279 00:10:06,481 --> 00:10:09,274 from five pounds down to something like two pounds. 280 00:10:09,359 --> 00:10:12,068 So the weight is gonna be removed 281 00:10:12,112 --> 00:10:14,112 from this sword by grinding. 282 00:10:14,197 --> 00:10:15,405 Being a judge on "forged in fire," 283 00:10:15,490 --> 00:10:18,617 a lot of times we see finale weapons come in 284 00:10:18,660 --> 00:10:20,952 that are grossly overweight. 285 00:10:20,996 --> 00:10:22,203 The first thing I feel when I pick this knife up 286 00:10:22,289 --> 00:10:24,831 is its weight. This thing is really heavy. 287 00:10:24,916 --> 00:10:26,458 Johnathan, at the end of the day, 288 00:10:26,501 --> 00:10:28,918 your halberd was heavy, more difficult to wield, 289 00:10:29,004 --> 00:10:30,962 and for those reasons, we have to let you go. 290 00:10:31,048 --> 00:10:33,381 Swords are not supposed to be heavy, 291 00:10:33,467 --> 00:10:36,134 so I'm gonna use all my experience as a judge 292 00:10:36,178 --> 00:10:39,846 to guide me in the weight distribution 293 00:10:39,931 --> 00:10:42,724 and usability of this final weapon. 294 00:10:42,809 --> 00:10:45,310 ♪ ♪ 295 00:10:45,354 --> 00:10:46,811 I like to listen to music while I work. 296 00:10:46,897 --> 00:10:49,439 It's the one thing that turns standing at a grinder 297 00:10:49,483 --> 00:10:53,818 from a very, very boring slog into a slightly boring slog. 298 00:10:53,862 --> 00:10:55,612 For anyone who's wondering, 299 00:10:55,697 --> 00:10:57,155 "I wonder what he's listening to 300 00:10:57,240 --> 00:10:58,657 while he's working," 301 00:10:58,742 --> 00:11:01,493 turns out--country music, and it's pretty awesome. 302 00:11:01,536 --> 00:11:02,535 [chuckles] 303 00:11:02,621 --> 00:11:04,162 I heart country. 304 00:11:04,206 --> 00:11:06,748 ♪ ♪ 305 00:11:06,833 --> 00:11:09,167 all right, well, it's the start of day eight, 306 00:11:09,252 --> 00:11:12,754 and today I just need to refine the sword blade 307 00:11:12,839 --> 00:11:14,464 just a little bit. 308 00:11:23,725 --> 00:11:25,475 Okay, so it's the start of day eight, 309 00:11:25,560 --> 00:11:28,520 and today I will start on the handle 310 00:11:28,605 --> 00:11:31,022 so that I have something to hold onto 311 00:11:31,066 --> 00:11:32,732 because it's a big, heavy sword, 312 00:11:32,818 --> 00:11:34,651 and holding it by the tang hurts. 313 00:11:34,695 --> 00:11:37,362 You can see the sketch I have here. 314 00:11:37,406 --> 00:11:39,906 This is the block that's gonna be the handle. 315 00:11:39,991 --> 00:11:41,991 This is the block that's gonna be 316 00:11:42,077 --> 00:11:44,202 the top and bottom guard. 317 00:11:44,287 --> 00:11:46,621 Boxwood tends to be a hard, durable wood. 318 00:11:46,707 --> 00:11:49,040 That's why it's been used since ancient times 319 00:11:49,084 --> 00:11:50,875 for sword handles. 320 00:11:50,919 --> 00:11:52,335 I think it's gonna go well with the brass 321 00:11:52,421 --> 00:11:54,087 that I'm gonna use for the fitting. 322 00:11:54,172 --> 00:11:58,258 I got some thicker brass here for two of the guards. 323 00:11:58,343 --> 00:11:59,759 I don't really have the money 324 00:11:59,845 --> 00:12:01,553 to make the gold fittings like the original, 325 00:12:01,638 --> 00:12:03,555 so I'm just gonna fake it in brass. 326 00:12:03,598 --> 00:12:06,224 I managed to get all of the component parts fit up. 327 00:12:06,309 --> 00:12:07,684 It's starting to come together 328 00:12:07,769 --> 00:12:09,310 as an attractive-looking handle. 329 00:12:09,396 --> 00:12:14,107 So it's the start of day 12--10--11? 330 00:12:14,192 --> 00:12:15,775 Shoot, I don't know. They're all melting together. 331 00:12:15,861 --> 00:12:18,570 I gotta get this blade quenched and tempered, 332 00:12:18,613 --> 00:12:20,405 making sure it's straight. 333 00:12:20,449 --> 00:12:22,532 Check out that even heat, baby. 334 00:12:22,617 --> 00:12:25,034 There's a reason there's the expression "the 11th hour." 335 00:12:25,120 --> 00:12:26,244 this is the 11th day, 336 00:12:26,329 --> 00:12:27,954 and I don't wanna start again right now. 337 00:12:28,039 --> 00:12:30,707 Here we go for the quench. 338 00:12:30,792 --> 00:12:34,419 My main concern in this quench is warps. 339 00:12:34,463 --> 00:12:36,504 The thing that makes the blade susceptible to warping 340 00:12:36,590 --> 00:12:39,549 is all of the different layers of different kinds of steel. 341 00:12:39,634 --> 00:12:41,301 There's wrought iron. There's 1095. 342 00:12:41,386 --> 00:12:43,344 There's 15n20. There's 1084. 343 00:12:43,430 --> 00:12:45,638 All of the different kinds of steels 344 00:12:45,724 --> 00:12:47,348 do different things when they're quenched, 345 00:12:47,434 --> 00:12:49,225 and I'm just nervous they're gonna do something 346 00:12:49,311 --> 00:12:50,351 I don't want 'em to do. 347 00:12:50,437 --> 00:12:51,394 ♪ ♪ 348 00:12:51,480 --> 00:12:53,021 might have a little warp. 349 00:12:53,106 --> 00:12:56,107 It's on both sides. It's very visible to me. 350 00:12:56,151 --> 00:12:57,650 I'm gonna see if I can just flex it 351 00:12:57,736 --> 00:12:59,235 and get that warp out of there. 352 00:12:59,321 --> 00:13:01,905 If I snap it, I want it to be on camera, 353 00:13:01,990 --> 00:13:03,490 but I don't wanna snap it. 354 00:13:03,575 --> 00:13:05,200 If I snap my blade in half right now, 355 00:13:05,285 --> 00:13:06,951 I'd be devastated. 356 00:13:06,995 --> 00:13:09,662 Pushing this blade and putting your weight into it is like-- 357 00:13:09,748 --> 00:13:12,916 imagine playing jenga on the subway. 358 00:13:13,001 --> 00:13:14,125 It's like that. 359 00:13:14,169 --> 00:13:16,127 ♪ ♪ 360 00:13:16,171 --> 00:13:17,587 kind of warp free. 361 00:13:17,672 --> 00:13:20,006 Nothing snapped, straight blade. 362 00:13:20,091 --> 00:13:23,134 I think I can see the light at the end of the tunnel here. 363 00:13:23,178 --> 00:13:25,804 Today is the final day of the build. 364 00:13:25,847 --> 00:13:28,348 It's time to start engraving the pattern 365 00:13:28,433 --> 00:13:29,641 into the pommel cap. 366 00:13:29,684 --> 00:13:31,518 It's got a very intricate pattern. 367 00:13:31,603 --> 00:13:34,479 The original sutton hoo sword has ribbon wire, 368 00:13:34,564 --> 00:13:36,314 and then in-between all the wires, 369 00:13:36,358 --> 00:13:39,484 they had cut garnets and set them all in place. 370 00:13:39,569 --> 00:13:40,985 I don't have the time for that, 371 00:13:41,071 --> 00:13:43,613 so what I'm gonna do is use an epoxy-based enamel 372 00:13:43,698 --> 00:13:45,782 to make it look similar to the original. 373 00:13:45,867 --> 00:13:48,159 Ready for etch. 374 00:13:49,162 --> 00:13:50,328 This is my favorite part. 375 00:13:50,372 --> 00:13:52,205 When I pull this sword out of the etch, 376 00:13:52,290 --> 00:13:55,291 I'm looking to see the results of all that pattern 377 00:13:55,335 --> 00:13:57,126 that I put into this sword. 378 00:13:57,212 --> 00:13:58,920 [laughs softly] 379 00:13:59,005 --> 00:14:01,256 I'm looking at this pattern as it's coming out of the acid, 380 00:14:01,341 --> 00:14:04,008 and all the hard work I put in has really paid off. 381 00:14:04,094 --> 00:14:05,677 It looks gorgeous. 382 00:14:05,762 --> 00:14:07,345 I'm pretty exhausted right now. 383 00:14:07,389 --> 00:14:09,347 I worked full tilt for two weeks, 384 00:14:09,391 --> 00:14:11,224 but I'm excited to get this thing finished. 385 00:14:11,309 --> 00:14:13,643 One thing that this experience has taught me 386 00:14:13,728 --> 00:14:17,021 is how easy of a job camera people have. 387 00:14:17,065 --> 00:14:18,523 I mean, come on. Just point and shoot. 388 00:14:18,608 --> 00:14:19,983 This is so simple. 389 00:14:20,026 --> 00:14:21,150 I'm really thankful. 390 00:14:21,236 --> 00:14:22,694 Dave drove me to make something 391 00:14:22,779 --> 00:14:24,195 I've always wanted to make, 392 00:14:24,239 --> 00:14:25,697 and now I've got it. [clicks tongue] 393 00:14:25,740 --> 00:14:28,533 ♪ ♪ 394 00:14:28,577 --> 00:14:29,993 well, guys, it's been two weeks, 395 00:14:30,078 --> 00:14:32,620 and here it is. 396 00:14:32,706 --> 00:14:34,330 Sutton hoo sword. 397 00:14:34,374 --> 00:14:36,749 - That is gorgeous. Look at that pattern. 398 00:14:36,835 --> 00:14:38,668 - Wow, ben, that sword looks beautiful. 399 00:14:38,753 --> 00:14:41,129 - The dimensions-- that thing looks huge. 400 00:14:41,214 --> 00:14:44,883 - Not the most nimbly weighted sword in the world. 401 00:14:44,926 --> 00:14:46,593 - It'll kick some butt, that's for sure. 402 00:14:46,678 --> 00:14:50,013 - So the plan is to test for strength on some bamboo, 403 00:14:50,056 --> 00:14:52,307 and then for sharpness, I have a whole lot 404 00:14:52,392 --> 00:14:55,018 of shipping boxes lying around, so I set one up here. 405 00:14:55,103 --> 00:14:57,020 I'm gonna see if I can't cut it in half. 406 00:14:57,105 --> 00:14:59,230 Make it easier to get in the recycling bin. 407 00:14:59,316 --> 00:15:00,440 - [laughs] 408 00:15:00,525 --> 00:15:02,483 - I am actually nervous about the testing. 409 00:15:02,569 --> 00:15:06,195 This is a long, very complex welded sword. 410 00:15:06,239 --> 00:15:07,739 Things might let go. 411 00:15:07,782 --> 00:15:09,991 I don't wanna break this thing. It took forever. 412 00:15:10,076 --> 00:15:12,285 - All right, man, good luck. - Thanks, man. 413 00:15:12,370 --> 00:15:13,828 Here we go. 414 00:15:13,914 --> 00:15:20,877 ♪ ♪ 415 00:15:24,466 --> 00:15:25,965 - oh, man, that's great. 416 00:15:26,051 --> 00:15:27,717 -The edge held up all right. 417 00:15:27,761 --> 00:15:29,469 Everything's still right and tight. 418 00:15:29,554 --> 00:15:31,346 So now it's to see how sharp the thing is. 419 00:15:31,431 --> 00:15:38,019 ♪ ♪ 420 00:15:38,104 --> 00:15:39,604 [laughs] 421 00:15:39,689 --> 00:15:42,482 well, there it is. 422 00:15:42,567 --> 00:15:44,734 - Good job, man. That's incredible. 423 00:15:44,819 --> 00:15:46,569 - That's a good job, ben. - Thank you, man. 424 00:15:46,613 --> 00:15:48,821 So yeah, now it's your turn, eh, j.? 425 00:15:48,907 --> 00:15:50,740 - All right, what do you got for me? 426 00:15:50,784 --> 00:15:52,784 - How about you make me a chopper 427 00:15:52,827 --> 00:15:54,744 out of material you've never used before. 428 00:15:54,829 --> 00:15:56,120 - You know, it's funny you mention that 429 00:15:56,206 --> 00:15:58,164 because there is a few different materials 430 00:15:58,249 --> 00:16:00,291 that I haven't tried yet that I've been wanting to. 431 00:16:00,377 --> 00:16:02,001 - And then I want you to go, 432 00:16:02,087 --> 00:16:04,337 like, full neilson on this thing 433 00:16:04,422 --> 00:16:05,838 and test it as hard as you can 434 00:16:05,924 --> 00:16:08,508 on some of the most devastating test media that you have. 435 00:16:08,593 --> 00:16:11,177 - I can do that because, if I don't 436 00:16:11,262 --> 00:16:13,888 do a serious strength test, fans are gonna crucify me 437 00:16:13,974 --> 00:16:15,848 for all the blades I've broken and damaged, 438 00:16:15,934 --> 00:16:18,935 so yeah, I'm gonna go hog wild on this thing, no doubt there. 439 00:16:18,979 --> 00:16:21,020 - Bud, I'm pretty sure we're all gonna love watching this. 440 00:16:21,106 --> 00:16:24,148 - All right, I'll get to it. - Good luck to you, brother. 441 00:16:24,192 --> 00:16:27,652 ♪ ♪ 442 00:16:27,737 --> 00:16:31,072 - I'm here in my own shop in towanda, pennsylvania. 443 00:16:31,157 --> 00:16:32,865 Ben did a great job on his weapon, 444 00:16:32,951 --> 00:16:35,159 and I'm planning on doing something just as good. 445 00:16:37,622 --> 00:16:40,164 I am fortunate enough, during this home build, 446 00:16:40,250 --> 00:16:42,667 to have my very lovely wife 447 00:16:42,711 --> 00:16:45,503 being my camera person and audio person. 448 00:16:45,588 --> 00:16:47,463 - Your eyes are looking like they're up in the ceiling. 449 00:16:47,549 --> 00:16:48,756 Look down more. 450 00:16:48,842 --> 00:16:50,341 - I'm looking right at that little thing. 451 00:16:50,427 --> 00:16:52,176 - I'm just telling you, look-- - I want a new camera person. 452 00:16:52,262 --> 00:16:54,137 She'll actually get to see what I do. 453 00:16:54,222 --> 00:16:56,347 Even though we've been together for 11 years... 454 00:16:56,391 --> 00:16:57,515 [laughter] 455 00:16:57,559 --> 00:16:58,975 I think she's spent an hour in my shop 456 00:16:59,060 --> 00:17:01,894 the whole 11 years. [chuckles] 457 00:17:01,980 --> 00:17:05,023 so ben challenged me to use steels I haven't used before. 458 00:17:05,066 --> 00:17:08,276 So what I'm planning on doing is making a canister 459 00:17:08,361 --> 00:17:10,945 out of drive chain and powdered steel, 460 00:17:11,031 --> 00:17:13,364 and then I'll peel the can off, slice it in half, 461 00:17:13,408 --> 00:17:16,325 and then san mai it to a piece of 80crv2, 462 00:17:16,411 --> 00:17:18,870 which we've seen quite a few smiths use 463 00:17:18,955 --> 00:17:20,621 on their finale weapons, 464 00:17:20,707 --> 00:17:23,374 but I actually haven't had a chance to use it yet. 465 00:17:23,460 --> 00:17:25,209 The biggest problem with the unknown steels 466 00:17:25,253 --> 00:17:27,962 is knowing how to properly heat them, forge them. 467 00:17:28,048 --> 00:17:29,756 I'm gonna fill it with the white out. 468 00:17:29,841 --> 00:17:30,965 So I can peel it. 469 00:17:31,051 --> 00:17:32,717 One of the biggest things with the canisters 470 00:17:32,761 --> 00:17:34,093 that I see contestants do wrong 471 00:17:34,179 --> 00:17:36,054 is not letting the white out dry. 472 00:17:36,139 --> 00:17:38,931 They don't wait long enough for that white out to dry. 473 00:17:39,017 --> 00:17:40,683 When they put their material in, 474 00:17:40,769 --> 00:17:42,602 it's gonna prevent the material from welding, 475 00:17:42,687 --> 00:17:45,188 and you still have parts of the can welded to a billet. 476 00:17:45,273 --> 00:17:47,899 The key to canister is patience, 477 00:17:47,942 --> 00:17:49,442 and that's been a difficult process 478 00:17:49,527 --> 00:17:50,526 for me to learn over the years 479 00:17:50,612 --> 00:17:51,944 'cause I'm not a patient person. 480 00:17:52,030 --> 00:17:53,988 - He's not a patient person at all. 481 00:17:54,074 --> 00:17:57,033 [laughs] 482 00:17:58,036 --> 00:17:59,327 whoa. - Scare you, honey? 483 00:17:59,412 --> 00:18:01,579 - Yeah, it startled me. 484 00:18:01,664 --> 00:18:03,164 - Fingers crossed, everybody. 485 00:18:03,249 --> 00:18:04,749 ♪ ♪ 486 00:18:04,793 --> 00:18:07,126 once I get that temperature that I think is right, 487 00:18:07,212 --> 00:18:08,795 I start squeezing that down. 488 00:18:08,880 --> 00:18:10,671 So now we're gonna let this cool, 489 00:18:10,757 --> 00:18:13,841 cut the ends off, and then pull the can off. 490 00:18:13,927 --> 00:18:16,094 ♪ ♪ 491 00:18:16,137 --> 00:18:17,553 when I'm peeling the can, for pride's sake, 492 00:18:17,597 --> 00:18:19,263 I wanna pull it off in one piece. 493 00:18:19,307 --> 00:18:21,516 ♪ ♪ 494 00:18:21,601 --> 00:18:23,267 ta-da. 495 00:18:23,311 --> 00:18:25,394 We got a nice, big chunk of steel here. 496 00:18:25,480 --> 00:18:27,105 That's day one. 497 00:18:27,148 --> 00:18:29,190 ♪ ♪ 498 00:18:29,275 --> 00:18:30,775 [light classical music] 499 00:18:30,819 --> 00:18:32,610 this is the kind of peaceful environment 500 00:18:32,654 --> 00:18:35,279 I'm used to working in. Hey, chubby. 501 00:18:35,323 --> 00:18:37,240 ♪ ♪ 502 00:18:37,325 --> 00:18:38,825 your mommy--what's that? I don't like it. 503 00:18:38,910 --> 00:18:40,535 Don't point it at me. - [laughs] 504 00:18:40,620 --> 00:18:42,120 ♪ ♪ 505 00:18:42,163 --> 00:18:43,746 - first thing I'm doing today is I'm going to take 506 00:18:43,790 --> 00:18:46,415 that canister billet and slice it in half, 507 00:18:46,501 --> 00:18:48,417 and I'm gonna use that for the sides 508 00:18:48,503 --> 00:18:51,963 of the san mai with a core of 80crv2. 509 00:18:52,048 --> 00:18:54,799 We have smiths doing canisters quite often, 510 00:18:54,884 --> 00:18:56,634 san mai quite often. 511 00:18:56,719 --> 00:18:58,970 I don't think we ever asked 'em to do both in the same build, 512 00:18:59,013 --> 00:19:00,596 so this is gonna be interesting. 513 00:19:03,351 --> 00:19:05,977 I wanna draw it out to match the core steel, 514 00:19:06,020 --> 00:19:07,979 and then get everything ground flat 515 00:19:08,022 --> 00:19:09,438 so it'll be easier to weld up. 516 00:19:09,524 --> 00:19:11,399 I love my hydraulic press. 517 00:19:11,484 --> 00:19:14,152 Preparation's one of the most important things 518 00:19:14,195 --> 00:19:17,321 in san mai--make sure everything's flat, clean 519 00:19:17,365 --> 00:19:20,074 because it will solve problems later on. 520 00:19:20,160 --> 00:19:22,952 - Sticking at all? - No, it's not sticking at all. 521 00:19:22,996 --> 00:19:25,079 I thought I had it pretty clean there. 522 00:19:25,165 --> 00:19:26,372 - You might wanna open it up 523 00:19:26,457 --> 00:19:28,166 and take a grinding wheel to it. 524 00:19:28,209 --> 00:19:29,458 Just try and strip anything out 525 00:19:29,502 --> 00:19:31,294 'cause once it's not sticking now, 526 00:19:31,337 --> 00:19:33,004 it's not going to. - Yeah, I know. 527 00:19:33,047 --> 00:19:35,131 - Taking a few extra minutes to clean up that steel 528 00:19:35,175 --> 00:19:36,674 is just a smart move. 529 00:19:36,759 --> 00:19:39,427 Now we're gonna forge weld it and actually make our san mai. 530 00:19:39,512 --> 00:19:44,891 ♪ ♪ 531 00:19:44,976 --> 00:19:47,727 what I'm really looking for is to see if everything 532 00:19:47,812 --> 00:19:49,520 is cooling at the same rate. 533 00:19:49,606 --> 00:19:51,022 If the outer layers start cooling 534 00:19:51,107 --> 00:19:52,565 faster than the inner layers, 535 00:19:52,650 --> 00:19:55,234 then, you know, it starts peel improperly. 536 00:19:55,320 --> 00:19:57,111 So nothing came apart. - Great. 537 00:19:57,197 --> 00:19:58,779 - Looks good. 538 00:19:58,823 --> 00:20:01,449 Tomorrow morning, we'll start actually forging out the blade. 539 00:20:01,534 --> 00:20:02,491 ♪ ♪ 540 00:20:03,578 --> 00:20:05,745 - dogs wanna come and help. 541 00:20:05,830 --> 00:20:07,246 - It's the beginning of day four. 542 00:20:07,332 --> 00:20:09,999 I'm not going for a set design or set style. 543 00:20:10,084 --> 00:20:12,543 I'm just going for a neilson chopper. 544 00:20:12,629 --> 00:20:15,004 - Throughout "forged in fire," the competition chopper 545 00:20:15,089 --> 00:20:16,964 has been a staple of the forge. 546 00:20:17,050 --> 00:20:19,634 Featuring a broad blade which rarely comes to a tip, 547 00:20:19,719 --> 00:20:22,011 they were designed for competition blade sports 548 00:20:22,096 --> 00:20:23,262 and cutting contests. 549 00:20:23,348 --> 00:20:24,889 However, crafting these weapons 550 00:20:24,974 --> 00:20:27,642 to ensure a perfect heat treat has proved difficult 551 00:20:27,727 --> 00:20:30,478 for previous competitors who have seen their blades 552 00:20:30,563 --> 00:20:33,064 chip, roll, and even snap during testing. 553 00:20:33,107 --> 00:20:34,065 ♪ ♪ 554 00:20:34,108 --> 00:20:35,566 it's got the standard tip. 555 00:20:35,610 --> 00:20:37,652 I'm gonna drop it down so you'll have 556 00:20:37,737 --> 00:20:41,072 a nice, little sweeping arc on the cutting edge. 557 00:20:41,157 --> 00:20:44,075 Choppers are not overly complicated, 558 00:20:44,118 --> 00:20:46,410 but it's just like a chef making a perfect egg. 559 00:20:46,496 --> 00:20:48,454 If you don't follow precisely, 560 00:20:48,539 --> 00:20:49,705 you could screw it up real easy. 561 00:20:49,791 --> 00:20:52,250 We are roughly 17 inches. 562 00:20:52,293 --> 00:20:54,418 ♪ ♪ 563 00:20:54,504 --> 00:20:56,754 beckie asked me about the marks on the side of the anvil. 564 00:20:56,798 --> 00:20:58,172 - Yeah, I didn't notice that before. 565 00:20:58,258 --> 00:20:59,757 - It's just a quick measurement reference 566 00:20:59,842 --> 00:21:01,592 so I don't have to keep getting a ruler and stuff like that. 567 00:21:01,636 --> 00:21:03,636 Contestants on the show can do this too. 568 00:21:03,721 --> 00:21:05,263 We never told them they can't write on the anvils. 569 00:21:05,306 --> 00:21:07,181 They're more than welcome to write on 'em. 570 00:21:07,267 --> 00:21:09,433 I like seeing berman marking his measurements down 571 00:21:09,519 --> 00:21:10,935 while his steel's heating up. 572 00:21:10,979 --> 00:21:13,479 - A lot of people go home because the perimeters. 573 00:21:13,564 --> 00:21:16,607 - Next step is to grind this blade down 574 00:21:16,651 --> 00:21:20,111 I had planned on leaving the forge flats 575 00:21:20,196 --> 00:21:21,821 which I do on a lot of my knives, 576 00:21:21,906 --> 00:21:23,447 but my wife wouldn't let me, 577 00:21:23,491 --> 00:21:25,116 so I had to leave the blade a little bit thicker, 578 00:21:25,201 --> 00:21:27,118 so it's gonna take me a little longer to grind it. 579 00:21:28,663 --> 00:21:29,954 - She didn't-- my wife didn't think 580 00:21:29,998 --> 00:21:32,623 the forge flats were pretty. [chuckles] 581 00:21:32,667 --> 00:21:33,791 ♪ ♪ 582 00:21:33,876 --> 00:21:35,960 progress is good. Everything seems fine. 583 00:21:36,004 --> 00:21:37,962 I don't see any creases in the steel or anything. 584 00:21:38,047 --> 00:21:40,298 It looks like a solid piece. 585 00:21:40,341 --> 00:21:42,049 - [quietly] beginning of day six. 586 00:21:42,135 --> 00:21:43,134 Today-- 587 00:21:43,177 --> 00:21:45,720 - what-- where's your microphone? 588 00:21:45,805 --> 00:21:47,722 - Ah [bleep]. 589 00:21:47,807 --> 00:21:48,681 ♪ ♪ 590 00:21:48,766 --> 00:21:50,933 the most crucial thing today 591 00:21:51,019 --> 00:21:53,269 is to get the heat treat correct. 592 00:21:53,354 --> 00:21:55,062 So I'm bringing this up to temperature-- 593 00:21:55,148 --> 00:21:57,982 about 600 plus degrees to warm up the blade, 594 00:21:58,026 --> 00:22:00,359 and I'm gonna use anti-scaling powder, 595 00:22:00,445 --> 00:22:02,486 which is something you don't normally see on the show. 596 00:22:02,572 --> 00:22:04,697 That'll actually coat the blade, 597 00:22:04,782 --> 00:22:06,949 but you definitely don't wanna breathe this stuff in. 598 00:22:07,035 --> 00:22:10,578 This anti-scaling powder tends to normally help with warping, 599 00:22:10,663 --> 00:22:13,497 but this is also gonna save me a lot of grinding time too 600 00:22:13,541 --> 00:22:15,124 because half of its gonna crack off 601 00:22:15,209 --> 00:22:16,542 in the quench oil, and the other half 602 00:22:16,627 --> 00:22:17,752 I can rinse off with hot water. 603 00:22:17,837 --> 00:22:20,087 So I'll have, basically, a shiny blade again. 604 00:22:20,173 --> 00:22:21,547 All right, this is it-- 605 00:22:21,632 --> 00:22:24,508 the quench, heart and soul of the blade. 606 00:22:24,552 --> 00:22:27,053 This is where it can come out beautiful 607 00:22:27,138 --> 00:22:29,638 or it can come out crooked, warped, crack in half, 608 00:22:29,724 --> 00:22:31,474 or really nice. 609 00:22:31,559 --> 00:22:34,018 Biggest problem with the unknown steels 610 00:22:34,062 --> 00:22:36,729 is all the steels move differently 611 00:22:36,814 --> 00:22:38,689 during heat, during forging. 612 00:22:38,733 --> 00:22:41,150 - I've never used 52100 steel before, 613 00:22:41,235 --> 00:22:42,818 so if you don't know how it acts, 614 00:22:42,862 --> 00:22:44,445 then anything could happen. 615 00:22:44,530 --> 00:22:45,654 ♪ ♪ 616 00:22:45,740 --> 00:22:47,156 - we definitely had an issue in round one 617 00:22:47,241 --> 00:22:49,116 with the heat treating. 618 00:22:49,202 --> 00:22:50,868 Just gotta cross your fingers and hope for the best. 619 00:22:53,373 --> 00:22:56,123 ♪ ♪ 620 00:22:56,209 --> 00:22:58,501 if this blade warps, I'm gonna be seriously pissed, 621 00:22:58,586 --> 00:23:00,461 and we might have to get the censor bleeping guys 622 00:23:00,546 --> 00:23:01,545 on here again. 623 00:23:01,589 --> 00:23:02,880 ♪ ♪ 624 00:23:02,924 --> 00:23:04,215 [bleep] 625 00:23:04,258 --> 00:23:05,925 ♪ ♪ 626 00:23:06,010 --> 00:23:07,510 I don't believe this. 627 00:23:07,595 --> 00:23:09,428 It warped huge. 628 00:23:09,514 --> 00:23:10,721 It's over a quarter of an inch 629 00:23:10,807 --> 00:23:12,223 from the tip away from the surface. 630 00:23:12,266 --> 00:23:13,808 There's no way I can grind this out. 631 00:23:13,893 --> 00:23:16,060 This is really putting me behind now. 632 00:23:16,145 --> 00:23:17,311 Very disappointing. 633 00:23:17,397 --> 00:23:18,979 ♪ ♪ 634 00:23:19,065 --> 00:23:20,356 [bleep]. 635 00:23:20,400 --> 00:23:23,943 We're about ready to chop into some bison jawbones, 636 00:23:24,028 --> 00:23:26,737 and, god, I hope this thing doesn't break in half. 637 00:23:26,781 --> 00:23:27,905 I'm gonna look like an idiot. 638 00:23:27,949 --> 00:23:29,240 ♪ ♪ 639 00:23:29,283 --> 00:23:31,617 - whoa! Warp. 640 00:23:31,702 --> 00:23:33,577 Frustrating like I cannot tell you. 641 00:23:33,663 --> 00:23:34,829 [imitates explosion] 642 00:23:34,914 --> 00:23:35,913 ♪ ♪ 643 00:23:40,670 --> 00:23:44,088 - this warped blade is really putting me behind now. 644 00:23:44,132 --> 00:23:46,048 I'm going to figure out how I wanna go ahead 645 00:23:46,092 --> 00:23:49,260 straightening this without breaking it in half, hopefully. 646 00:23:49,303 --> 00:23:50,302 ♪ ♪ 647 00:23:50,388 --> 00:23:52,012 because there's such a big warp, 648 00:23:52,098 --> 00:23:54,765 I think the steel's gonna do it again, 649 00:23:54,851 --> 00:23:57,726 so I'm going to overcompensate the blade 650 00:23:57,812 --> 00:23:59,228 in the other direction. 651 00:23:59,313 --> 00:24:01,439 So hopefully when I quench the blade this time, 652 00:24:01,482 --> 00:24:03,274 it'll warp itself straight. 653 00:24:03,317 --> 00:24:06,193 ♪ ♪ 654 00:24:06,279 --> 00:24:09,071 so if this doesn't go right, I'm gonna have to start over, 655 00:24:09,115 --> 00:24:11,449 but first I'll probably bash this blade into little pieces 656 00:24:11,534 --> 00:24:12,867 and make it my next canister. 657 00:24:12,952 --> 00:24:14,535 ♪ ♪ 658 00:24:14,620 --> 00:24:17,121 stick blade. We tricked the steel. 659 00:24:17,165 --> 00:24:19,123 Blade worked itself straight. 660 00:24:19,208 --> 00:24:22,126 There is just a tiny, little bend at the tip 661 00:24:22,170 --> 00:24:23,794 but easily within grinder range. 662 00:24:23,838 --> 00:24:24,962 Easy to fix. 663 00:24:25,006 --> 00:24:26,547 I'm very happy about this. 664 00:24:26,632 --> 00:24:28,299 ♪ ♪ 665 00:24:32,138 --> 00:24:34,763 you gotta tell me to start. [both laugh] 666 00:24:34,849 --> 00:24:36,557 beginning of day eight. 667 00:24:36,642 --> 00:24:37,975 I've got the blade straightened out, 668 00:24:38,060 --> 00:24:40,311 got it re-hardened. It's looking good. 669 00:24:40,396 --> 00:24:42,730 All I gotta do is blue the spine 670 00:24:42,815 --> 00:24:44,315 so we've got a little shock absorption, 671 00:24:44,400 --> 00:24:46,942 blue the tang, and finish grinding. 672 00:24:47,028 --> 00:24:50,738 Whenever somebody says "you can't hit steel"... 673 00:24:50,823 --> 00:24:57,703 ♪ ♪ 674 00:24:57,788 --> 00:25:00,581 you can. Now the tang's straight. 675 00:25:00,666 --> 00:25:03,334 Getting a final grind on. 676 00:25:03,377 --> 00:25:05,669 I'm liking where I'm at. Steel looks good. 677 00:25:05,755 --> 00:25:07,713 I mean, I don't see seams or creases 678 00:25:07,798 --> 00:25:10,841 or anything like that, so I'm really happy. 679 00:25:10,885 --> 00:25:12,259 ♪ ♪ 680 00:25:12,345 --> 00:25:13,636 it's day 19. 681 00:25:13,721 --> 00:25:16,889 - It's not day-- [laughs] 682 00:25:16,974 --> 00:25:19,350 - today I'm going to etch the blade 683 00:25:19,393 --> 00:25:20,851 and see what it actually looks like. 684 00:25:20,937 --> 00:25:22,770 It's like christmas for knifemakers. 685 00:25:22,855 --> 00:25:24,188 ♪ ♪ 686 00:25:24,273 --> 00:25:27,566 you can see the pattern. - Oh, yeah. 687 00:25:27,652 --> 00:25:29,568 - It's got a nice, dark core steel. 688 00:25:29,654 --> 00:25:31,946 The drive chain and the powdered steel 689 00:25:32,031 --> 00:25:33,447 came out nice and shiny. 690 00:25:33,533 --> 00:25:35,866 You can actually see the links in there in certain parts, 691 00:25:35,910 --> 00:25:37,993 so I'm happy with this. This looks cool. 692 00:25:38,079 --> 00:25:40,037 Now it's time to work on my handle. 693 00:25:40,081 --> 00:25:42,206 Again, with the unknown materials, 694 00:25:42,291 --> 00:25:44,833 I've got ultrex, which is g10 695 00:25:44,919 --> 00:25:47,711 layered with thin pieces of rubber. 696 00:25:47,755 --> 00:25:50,631 I'm not normally big on the synthetic materials, 697 00:25:50,716 --> 00:25:52,883 but this one really caught my interest 698 00:25:52,927 --> 00:25:54,718 because having a big chopper, 699 00:25:54,762 --> 00:25:56,011 you get that grip with the rubber 700 00:25:56,097 --> 00:25:58,180 and a bit of shock absorption also, 701 00:25:58,266 --> 00:26:01,392 so you get less of that sting traveling up your wrist. 702 00:26:01,435 --> 00:26:03,686 I've roughed out the ultrex. 703 00:26:03,771 --> 00:26:06,480 I'm gonna shape it a little more evenly, 704 00:26:06,566 --> 00:26:08,440 and then I always use handle bolts 705 00:26:08,526 --> 00:26:10,401 because there's a mechanical connection that way. 706 00:26:10,444 --> 00:26:12,111 ♪ ♪ 707 00:26:12,196 --> 00:26:14,071 the challenge was fun. I enjoyed it. 708 00:26:14,115 --> 00:26:15,281 I had a couple minor hiccups, 709 00:26:15,366 --> 00:26:16,991 but overall it went pretty well. 710 00:26:17,076 --> 00:26:18,534 I like the way the piece came out. 711 00:26:18,619 --> 00:26:20,578 It seems like it's gonna hold up well. 712 00:26:20,621 --> 00:26:22,246 The handle came out great, 713 00:26:22,290 --> 00:26:24,623 and the pattern is something I hadn't done, so yeah, 714 00:26:24,709 --> 00:26:26,584 I'm looking forward to showing it to ben and dave 715 00:26:26,627 --> 00:26:27,835 and having some fun with it. 716 00:26:27,920 --> 00:26:30,421 ♪ ♪ 717 00:26:30,464 --> 00:26:32,590 hey, guys, it's been two weeks, and I'm back. 718 00:26:32,633 --> 00:26:34,633 - Hey. - Hey, j. 719 00:26:34,719 --> 00:26:36,594 Did you have fun? - I had a blast. 720 00:26:36,679 --> 00:26:38,721 So here's my san mai chopper. 721 00:26:38,806 --> 00:26:41,932 It's just under a 13-inch cutting edge. 722 00:26:41,976 --> 00:26:44,268 The core is 80crv2-- 723 00:26:44,353 --> 00:26:46,478 new steel for me to play around with, 724 00:26:46,564 --> 00:26:50,107 and I took some drive chain and made a canister damascus 725 00:26:50,151 --> 00:26:52,860 and that's what I clad on both sides of the core. 726 00:26:52,945 --> 00:26:55,613 - How'd you like that ultrex? - The ultrex is nice. 727 00:26:55,698 --> 00:26:57,448 It gives you really good grip. - Cool. 728 00:26:57,491 --> 00:26:59,783 - And I did a little work for a meat packing plant 729 00:26:59,869 --> 00:27:01,285 a while back, and they were nice enough 730 00:27:01,370 --> 00:27:03,621 to give me these lovely bison jawbones. 731 00:27:03,706 --> 00:27:05,372 - [laughs] 732 00:27:05,458 --> 00:27:07,666 - I've got two of 'em strapped to a table over there. 733 00:27:07,752 --> 00:27:10,794 - Well, that looks like some pretty brutal material, j. 734 00:27:10,838 --> 00:27:12,254 Good luck with it. 735 00:27:12,298 --> 00:27:14,256 - Let's have some fun. 736 00:27:14,342 --> 00:27:15,591 - Remember, j., 737 00:27:15,676 --> 00:27:17,509 it's not what your blade does to those bison bones, 738 00:27:17,595 --> 00:27:19,470 but what those bison bones do to your blade. 739 00:27:22,016 --> 00:27:25,309 [laughter] 740 00:27:26,228 --> 00:27:29,229 - so we're about ready to chop into some bison jawbones, 741 00:27:29,315 --> 00:27:31,857 and, god, I hope this thing doesn't break in half. 742 00:27:31,942 --> 00:27:33,150 I'm gonna look like an idiot. 743 00:27:33,194 --> 00:27:37,154 ♪ ♪ 744 00:27:41,327 --> 00:27:42,826 ♪ ♪ 745 00:27:42,912 --> 00:27:45,704 - we're about ready to chop into some bison jawbones, 746 00:27:45,790 --> 00:27:49,041 and my plan is to try and not break my new knife. 747 00:27:49,126 --> 00:27:53,170 ♪ ♪ 748 00:27:53,214 --> 00:27:54,963 - [laughs] 749 00:27:55,049 --> 00:27:57,091 - well, that didn't work the way I wanted it to. 750 00:27:57,176 --> 00:27:58,300 - It worked pretty good. 751 00:27:58,386 --> 00:28:05,349 ♪ ♪ 752 00:28:07,812 --> 00:28:09,061 - whoa. 753 00:28:09,146 --> 00:28:10,688 ♪ ♪ 754 00:28:11,899 --> 00:28:13,899 - wow. - That was wicked. 755 00:28:13,984 --> 00:28:15,234 ♪ ♪ 756 00:28:15,319 --> 00:28:17,653 - well, she's still tight, straight. 757 00:28:17,697 --> 00:28:20,614 No damage to the edge... 758 00:28:20,700 --> 00:28:22,491 And still sharp. 759 00:28:22,576 --> 00:28:24,493 ♪ ♪ 760 00:28:24,578 --> 00:28:26,453 - well, j., you really knocked that out of the park, man. 761 00:28:26,539 --> 00:28:28,080 Nice job. - Good job, man. 762 00:28:28,165 --> 00:28:29,581 - Appreciate it. 763 00:28:29,625 --> 00:28:33,043 All right, mr. Baker, I got a challenge for you, bud. 764 00:28:33,129 --> 00:28:35,254 - Oh, boy, now, I'm on the chopping block. 765 00:28:35,339 --> 00:28:37,881 Okay, all right, what's the challenge gonna be? 766 00:28:37,967 --> 00:28:40,134 - If you remember, we had somebody come on the show 767 00:28:40,219 --> 00:28:44,722 and do a scottish basket hilt that really tore my wrist up 768 00:28:44,807 --> 00:28:46,682 and sent me to the er. 769 00:28:46,767 --> 00:28:50,060 Scale and all that stuff is one of your things, 770 00:28:50,146 --> 00:28:52,438 so make me a scottish basket hilt 771 00:28:52,523 --> 00:28:54,231 that won't tear somebody's arm up. 772 00:28:54,275 --> 00:28:55,232 - [laughs] 773 00:28:55,317 --> 00:28:56,900 okay, all right, I'm down for that. 774 00:28:56,944 --> 00:28:59,695 The basket hilt originated in scotland 775 00:28:59,780 --> 00:29:01,989 in the 17th century and include 776 00:29:02,074 --> 00:29:04,032 an intricate enclosed guard 777 00:29:04,118 --> 00:29:06,034 intended to protect the user's hand. 778 00:29:06,120 --> 00:29:08,078 Although primarily used for defense, 779 00:29:08,164 --> 00:29:10,414 the basket hilt also had the ability to punch. 780 00:29:10,499 --> 00:29:13,208 The importance of properly designing the basket hilt 781 00:29:13,294 --> 00:29:16,170 is crucial in crafting a safe and effective weapon-- 782 00:29:16,255 --> 00:29:18,505 as seen in previous "forged in fire" competition 783 00:29:18,591 --> 00:29:20,758 when a design flaw injured j.'s wrist. 784 00:29:20,843 --> 00:29:22,926 - That sounds like a good challenge, dave. 785 00:29:23,012 --> 00:29:24,178 - It's gonna be really important 786 00:29:24,263 --> 00:29:26,180 that I get the scale, the weight, 787 00:29:26,265 --> 00:29:27,431 and the balance right 788 00:29:27,516 --> 00:29:29,266 because I'm gonna be doing the testing, 789 00:29:29,351 --> 00:29:30,559 and I really don't want a hand-breaker. 790 00:29:30,603 --> 00:29:32,186 - Looking forward to it. 791 00:29:32,271 --> 00:29:35,230 - Okay, I guess it's my turn to head into the shop. 792 00:29:35,274 --> 00:29:37,733 I will see you guys in two weeks. 793 00:29:37,818 --> 00:29:44,615 ♪ ♪ 794 00:29:45,910 --> 00:29:47,075 I'm here at my new place 795 00:29:47,161 --> 00:29:48,994 on the northern neck of virginia. 796 00:29:49,079 --> 00:29:52,080 My barn there is my workspace. 797 00:29:52,166 --> 00:29:54,875 I'm about, you know, 1/3 the way through building 798 00:29:54,960 --> 00:29:56,794 my new shop space here, 799 00:29:56,879 --> 00:30:00,047 so if the self-shooting from home isn't enough, 800 00:30:00,132 --> 00:30:03,425 I've actually got large pieces of equipment being delivered 801 00:30:03,511 --> 00:30:04,843 while I'm trying to do this. 802 00:30:04,929 --> 00:30:07,721 J. Has challenged me to make a scottish basket hilt. 803 00:30:07,807 --> 00:30:09,473 My goal is to get this 804 00:30:09,558 --> 00:30:11,975 as historically accurate as I can. 805 00:30:12,019 --> 00:30:14,102 The blade is a very straightforward 806 00:30:14,188 --> 00:30:16,104 broadsword blade, so it'll have double edges 807 00:30:16,190 --> 00:30:17,940 and a deep fuller down the center. 808 00:30:18,025 --> 00:30:20,776 It's the guard itself that becomes difficult-- 809 00:30:20,861 --> 00:30:24,446 getting that dimension and scale perfect. 810 00:30:24,532 --> 00:30:27,282 And as the historical recreations specialist 811 00:30:27,368 --> 00:30:30,285 on the show, it's important for me to nail it. 812 00:30:30,371 --> 00:30:33,330 I start with creating my blade.... 813 00:30:33,374 --> 00:30:35,123 Voilà, five pieces. 814 00:30:35,209 --> 00:30:39,002 Because the hilt has to fit and grow around that blade. 815 00:30:39,088 --> 00:30:41,380 So I start by stacking up my metals. 816 00:30:41,465 --> 00:30:43,632 I've got 15n20 and 1095. 817 00:30:43,717 --> 00:30:46,009 So I wanna do this sword with a damascus blade 818 00:30:46,095 --> 00:30:51,056 because, well, in truth I'm doing a damascus blade 819 00:30:51,141 --> 00:30:52,933 on this sword because if I don't, 820 00:30:53,018 --> 00:30:54,977 ben and j. Will never let me live it down. 821 00:30:55,062 --> 00:30:57,437 Instead of the basket hilt sword, 822 00:30:57,523 --> 00:30:59,398 it will be the basket guilt sword. 823 00:30:59,483 --> 00:31:01,358 [laughs] 824 00:31:01,443 --> 00:31:04,027 when you forge weld, you want those clean pieces 825 00:31:04,113 --> 00:31:06,822 to bind to one another, so it's really important 826 00:31:06,907 --> 00:31:08,532 to get that material as clean as you can 827 00:31:08,617 --> 00:31:10,993 before you weld so you don't get 828 00:31:11,078 --> 00:31:12,536 the buildup of forge scale. 829 00:31:12,621 --> 00:31:15,831 Well, I'm worried that mike didn't do enough clean-up work 830 00:31:15,916 --> 00:31:17,457 on those pieces of steel. 831 00:31:17,543 --> 00:31:19,334 - Damn it, I opened up. 832 00:31:19,420 --> 00:31:20,878 - Mike hasn't cleaned any of that material. 833 00:31:20,921 --> 00:31:22,713 It just won't stick. 834 00:31:22,756 --> 00:31:25,173 So that kind of problem-solving skills 835 00:31:25,259 --> 00:31:27,217 that make champions on "forged in fire." 836 00:31:28,888 --> 00:31:30,679 all the welds held beautifully. 837 00:31:30,764 --> 00:31:32,347 Now I can just draw that billet out 838 00:31:32,433 --> 00:31:33,765 to the length I need. 839 00:31:33,851 --> 00:31:35,434 ♪ ♪ 840 00:31:35,519 --> 00:31:38,604 my camerawork might be either very static 841 00:31:38,689 --> 00:31:43,692 or there might be a lot of that--whoa-- 842 00:31:43,736 --> 00:31:45,319 camera falling over kind of thing. 843 00:31:45,404 --> 00:31:48,697 Hopefully not. This is the studio's camera. 844 00:31:48,782 --> 00:31:49,781 ♪ ♪ 845 00:31:49,867 --> 00:31:51,617 it's day three of my build. 846 00:31:51,702 --> 00:31:53,118 ♪ ♪ 847 00:31:53,203 --> 00:31:55,203 I'm drawing my blade out, and it looks really good, 848 00:31:55,289 --> 00:31:57,164 so it's time to start shaping. 849 00:31:57,249 --> 00:32:01,501 Finished, this blade should be between 31 to 31 1/2 inches 850 00:32:01,587 --> 00:32:06,173 with a 2-inch base, a wide fuller, rounded tip, 851 00:32:06,258 --> 00:32:08,258 and it should weigh in 852 00:32:08,344 --> 00:32:11,094 at maybe a pound and a couple of ounces. 853 00:32:11,180 --> 00:32:13,972 Let's change that camera angle, shall we? 854 00:32:14,058 --> 00:32:16,058 Call the camera department. What? 855 00:32:16,143 --> 00:32:18,560 You are the camera department. Ah, crap. 856 00:32:18,646 --> 00:32:20,812 ♪ ♪ 857 00:32:20,898 --> 00:32:23,065 the next stage is to press the fuller 858 00:32:23,150 --> 00:32:24,691 down the center of this blade. 859 00:32:24,777 --> 00:32:27,110 It's gonna widen the blade up, which I need to do 860 00:32:27,196 --> 00:32:28,403 because right now it's a little thinner 861 00:32:28,447 --> 00:32:30,030 than I want it to... [bird squeaking] 862 00:32:30,115 --> 00:32:31,239 want it to be. 863 00:32:31,325 --> 00:32:32,824 Sorry, that was me looking at a vulture 864 00:32:32,910 --> 00:32:34,117 that was just flying over my head. 865 00:32:34,203 --> 00:32:35,077 [vulture squawks] 866 00:32:35,162 --> 00:32:36,328 there she is. She's still hot. 867 00:32:36,413 --> 00:32:38,747 Rough forged, a fairly well shaped blade 868 00:32:38,791 --> 00:32:40,499 that will be ready for heat treat. 869 00:32:40,584 --> 00:32:43,126 ♪ ♪ 870 00:32:43,212 --> 00:32:47,255 this is called being proactive while thermocycling 871 00:32:47,341 --> 00:32:49,424 make use of the time, a little study. 872 00:32:49,510 --> 00:32:50,384 ♪ ♪ 873 00:32:50,469 --> 00:32:52,344 [snores] 874 00:32:52,429 --> 00:32:54,888 ♪ ♪ 875 00:32:54,974 --> 00:32:57,849 blade's up to temperature. It looks great, and I quench. 876 00:32:57,935 --> 00:33:00,769 ♪ ♪ 877 00:33:00,854 --> 00:33:03,313 the longer the blade you do, the larger the chances 878 00:33:03,399 --> 00:33:05,273 that you're going to have some kind of warping 879 00:33:05,359 --> 00:33:07,442 so this has gotta go right. 880 00:33:07,528 --> 00:33:08,819 ♪ ♪ 881 00:33:08,904 --> 00:33:10,362 whoa! 882 00:33:10,447 --> 00:33:12,656 It's warped near the tang. 883 00:33:12,741 --> 00:33:14,116 Warp. 884 00:33:14,201 --> 00:33:16,535 Frustrating like I cannot tell you. 885 00:33:16,620 --> 00:33:17,828 Do that again. 886 00:33:17,871 --> 00:33:19,621 It's back in the oven, re-quench. 887 00:33:19,707 --> 00:33:22,457 Well, that sucked, but quench it again. 888 00:33:22,543 --> 00:33:23,959 You know, every time you quench, 889 00:33:24,044 --> 00:33:26,044 you have a risk of creating more problems... 890 00:33:26,130 --> 00:33:27,295 ♪ ♪ 891 00:33:27,381 --> 00:33:28,547 whether it's stressing the blade 892 00:33:28,632 --> 00:33:29,798 or creating another warp 893 00:33:29,883 --> 00:33:31,466 that you're gonna have to take out 894 00:33:31,510 --> 00:33:33,301 or re-warping the same thing. 895 00:33:33,387 --> 00:33:35,178 ♪ ♪ 896 00:33:35,264 --> 00:33:37,597 whoa! [imitates explosion] 897 00:33:43,814 --> 00:33:45,272 - whoa! 898 00:33:45,357 --> 00:33:48,483 Well, that sucked, but quench it again. 899 00:33:48,569 --> 00:33:49,818 It's that moment of truth. 900 00:33:49,903 --> 00:33:51,361 I mean, every time you quench 901 00:33:51,405 --> 00:33:53,196 you run the risk of doing more damage to the blade. 902 00:33:53,240 --> 00:33:54,656 [imitates explosion] 903 00:33:54,742 --> 00:33:56,616 as I'm pulling it out, all I'm doing is I'm hoping 904 00:33:56,702 --> 00:33:58,910 that it's spot on, and boom, it's dead straight. 905 00:33:58,996 --> 00:33:59,953 It looks good. 906 00:34:00,039 --> 00:34:01,288 All right. [imitates explosion] 907 00:34:01,373 --> 00:34:03,040 blade quenched. 908 00:34:03,125 --> 00:34:05,208 That's it for today. 909 00:34:11,341 --> 00:34:12,716 Yeehaw. 910 00:34:12,801 --> 00:34:15,802 I've got weights, measurements, balance point, 911 00:34:15,888 --> 00:34:17,512 all dialed in. 912 00:34:17,598 --> 00:34:19,514 With the blade being ready, it's time to move on 913 00:34:19,600 --> 00:34:21,516 to that guard, which is very intricate 914 00:34:21,560 --> 00:34:23,351 and is going to take a lot of work. 915 00:34:23,437 --> 00:34:25,520 One of the most interesting things that you find 916 00:34:25,564 --> 00:34:27,230 when you pick up one of these 917 00:34:27,316 --> 00:34:30,025 is that the top of the basket is not flat. 918 00:34:30,110 --> 00:34:32,694 It actually angles back towards your wrist, 919 00:34:32,780 --> 00:34:35,530 which is the natural position your hand is in. 920 00:34:35,616 --> 00:34:37,783 It's as much a weapon as the blade is. 921 00:34:37,868 --> 00:34:39,951 You can punch with it. You can guard with it. 922 00:34:40,037 --> 00:34:41,578 It's a shield. 923 00:34:41,663 --> 00:34:44,915 I'm actually gonna try making this specific guard right here. 924 00:34:44,958 --> 00:34:46,124 It's very elaborate. 925 00:34:46,210 --> 00:34:48,085 It's got a lot of cut up file work on it. 926 00:34:48,170 --> 00:34:51,213 Instead of just doing a scottish basket hilt, 927 00:34:51,298 --> 00:34:52,547 I've decided to do 928 00:34:52,633 --> 00:34:54,966 an allan-inspired scottish basket hilt. 929 00:34:55,052 --> 00:34:58,386 The allans made very unique shaped basket hilts 930 00:34:58,472 --> 00:34:59,763 that were extremely ornate-- 931 00:34:59,848 --> 00:35:02,015 just absolutely beautiful craftsmanship. 932 00:35:02,101 --> 00:35:03,767 So here we go. 933 00:35:03,811 --> 00:35:06,978 I used a plasma cutter to open up the lines 934 00:35:07,064 --> 00:35:08,772 that are the openings in the guard. 935 00:35:08,816 --> 00:35:09,856 Now it's file time. 936 00:35:09,942 --> 00:35:11,817 We'll see how I can open this up. 937 00:35:11,902 --> 00:35:13,777 Used my template here to draw the lines out, 938 00:35:13,862 --> 00:35:16,613 and now it's basically using the rotary tool 939 00:35:16,657 --> 00:35:19,116 to carve out all these openings, 940 00:35:19,201 --> 00:35:21,034 get them as clean as I possibly can 941 00:35:21,120 --> 00:35:23,161 before I go to a hand file. 942 00:35:23,247 --> 00:35:26,581 Hopefully, tomorrow, finish the guard completely. 943 00:35:26,667 --> 00:35:28,583 Just gonna keep things moving. 944 00:35:28,669 --> 00:35:29,626 ♪ ♪ 945 00:35:31,505 --> 00:35:33,130 ugh, yeah. 946 00:35:33,215 --> 00:35:36,216 Pardon me while I adjust this. [chuckles] 947 00:35:36,301 --> 00:35:39,010 I'm looking at the hilt. The dimensions aren't right. 948 00:35:39,096 --> 00:35:41,930 The guard part here is too cylindrical, 949 00:35:42,015 --> 00:35:44,432 so I need to hammer some dimension into it. 950 00:35:44,518 --> 00:35:46,184 I need it to be a little bit wider. 951 00:35:46,270 --> 00:35:47,727 So basically, I'm gonna heat it up 952 00:35:47,813 --> 00:35:49,521 and stretch it out just a little bit 953 00:35:49,606 --> 00:35:51,231 using the bottom of an old cylinder 954 00:35:51,316 --> 00:35:52,732 that I cut off. 955 00:35:52,818 --> 00:35:55,610 I drive that down in, and I get a bit of a belly 956 00:35:55,696 --> 00:35:58,029 into the guard, which is what I'm looking for. 957 00:35:58,115 --> 00:36:00,115 See that curvature now? 958 00:36:00,159 --> 00:36:02,742 That is so much sexier than it was. 959 00:36:02,828 --> 00:36:05,370 So onto the next adventure 960 00:36:05,455 --> 00:36:08,790 as I try not to kill myself in here. 961 00:36:08,834 --> 00:36:10,750 Now, my handle is going to be 962 00:36:10,836 --> 00:36:13,378 a leather-wrapped spiral handle. 963 00:36:13,463 --> 00:36:14,921 The core material for the handle, 964 00:36:15,007 --> 00:36:16,381 I can use whatever I want, 965 00:36:16,466 --> 00:36:18,592 so I'm going to go ahead and use 966 00:36:18,677 --> 00:36:19,968 this aluminum micarta. 967 00:36:20,053 --> 00:36:21,469 It's pretty much bond-proof material. 968 00:36:21,555 --> 00:36:22,554 That way I don't have to worry 969 00:36:22,639 --> 00:36:24,389 about the handle cracking ever. 970 00:36:24,474 --> 00:36:26,099 ♪ ♪ 971 00:36:26,185 --> 00:36:27,851 all right, so as a handle, it's still really chunky, 972 00:36:27,936 --> 00:36:29,394 but you can see in a couple of minutes, 973 00:36:29,479 --> 00:36:30,687 you got the core. 974 00:36:30,731 --> 00:36:33,190 This gives me a starting place to build from 975 00:36:33,233 --> 00:36:34,608 while I'm putting the guard together. 976 00:36:34,693 --> 00:36:36,026 Tomorrow's a big day. 977 00:36:36,111 --> 00:36:39,487 Tomorrow I do the fit up, so I'm going to enjoy 978 00:36:39,573 --> 00:36:42,574 the rest of my bourbon and play guitar. 979 00:36:42,659 --> 00:36:46,953 ♪ ♪ 980 00:36:47,039 --> 00:36:48,872 I need bourbon. 981 00:36:51,418 --> 00:36:52,584 ♪ ta-da ♪ 982 00:36:52,669 --> 00:36:54,169 I have the handle made. 983 00:36:54,254 --> 00:36:57,881 Everything feels pretty good in my hand, but it's too heavy. 984 00:36:57,966 --> 00:36:59,424 The micarta's a little heavy. 985 00:36:59,509 --> 00:37:01,676 I'm trying to save every ounce I can get, 986 00:37:01,762 --> 00:37:04,179 so I've got this piece of manzanita. 987 00:37:04,264 --> 00:37:06,848 It's a lot lighter than the other material. 988 00:37:06,934 --> 00:37:08,683 I'm just fighting for every ounce. 989 00:37:08,727 --> 00:37:10,602 I wanna get this thing just right. 990 00:37:10,687 --> 00:37:12,312 It's about right. 991 00:37:12,397 --> 00:37:13,730 [clicks tongue] 992 00:37:13,815 --> 00:37:15,732 I've got the new handle placed on there, 993 00:37:15,817 --> 00:37:17,734 which puts the pommel at the right height, 994 00:37:17,819 --> 00:37:19,903 and then it's really just finish work from that point on. 995 00:37:19,988 --> 00:37:22,155 Still wanna drop a couple of ounces out of this, 996 00:37:22,241 --> 00:37:24,032 but you can see how my hand sits in there. 997 00:37:24,117 --> 00:37:26,159 There's plenty of room for my wrist. 998 00:37:26,245 --> 00:37:28,078 You can see the-- [laughs] 999 00:37:28,121 --> 00:37:30,080 I just don't have a tall enough ceiling in here. 1000 00:37:30,165 --> 00:37:31,665 Do that. There we go. 1001 00:37:31,750 --> 00:37:33,583 [laughs] 1002 00:37:33,669 --> 00:37:36,628 but anyway, you can see it's all coming together. 1003 00:37:36,713 --> 00:37:38,755 Almost there. Close. 1004 00:37:38,799 --> 00:37:42,050 Now I start grinding into the hilt itself, 1005 00:37:42,135 --> 00:37:44,719 putting decorative lines on the hilt. 1006 00:37:44,805 --> 00:37:46,763 And my creaky chair. 1007 00:37:46,848 --> 00:37:49,557 Grinding out any welds that are a little bit thick-- 1008 00:37:49,643 --> 00:37:52,310 anything I can do to pick up a couple of ounces. 1009 00:37:52,396 --> 00:37:53,645 So the next... 1010 00:37:53,730 --> 00:37:55,230 ♪ ♪ 1011 00:37:55,315 --> 00:37:56,898 few hours.. 1012 00:37:56,984 --> 00:37:58,692 ♪ ♪ 1013 00:37:58,777 --> 00:38:01,236 will be all about this. 1014 00:38:02,698 --> 00:38:05,448 All right, I need three more pieces 1015 00:38:05,534 --> 00:38:06,992 to finish this guard. 1016 00:38:07,077 --> 00:38:08,868 I'm taking quite a bit of time to make this hilt, 1017 00:38:08,954 --> 00:38:12,247 but there are so many things that make a difference 1018 00:38:12,332 --> 00:38:15,500 between what you might pick up as a production model 1019 00:38:15,585 --> 00:38:18,753 and a historically accurate recreation, 1020 00:38:18,839 --> 00:38:20,255 which is what I'm shooting for. 1021 00:38:20,299 --> 00:38:22,632 There's three pieces that tie 1022 00:38:22,718 --> 00:38:25,677 the base of this guard together, 1023 00:38:25,762 --> 00:38:28,430 and basically they're just little loops of steel, 1024 00:38:28,515 --> 00:38:31,808 so what I'm gonna do is take this piece 1025 00:38:31,893 --> 00:38:36,021 of 1/4-inch rod and just gently pull it around. 1026 00:38:36,106 --> 00:38:38,481 A lot of swords, the guard is one piece. 1027 00:38:38,525 --> 00:38:40,150 This has 12 pieces. 1028 00:38:40,235 --> 00:38:43,194 All 12 of those pieces have to fit together 1029 00:38:43,280 --> 00:38:45,280 and not only be aesthetically pleasing 1030 00:38:45,365 --> 00:38:46,656 but be ergonomic. 1031 00:38:46,700 --> 00:38:47,991 ♪ ta-da ♪ 1032 00:38:48,076 --> 00:38:50,243 yeah, it's a piece of work. I kind of set myself up. 1033 00:38:50,329 --> 00:38:51,619 [laughs] 1034 00:38:51,705 --> 00:38:53,538 now it's polish time. 1035 00:38:53,623 --> 00:38:56,166 ♪ ♪ 1036 00:38:56,209 --> 00:38:58,084 [knocking] 1037 00:38:58,170 --> 00:38:59,169 hello. 1038 00:38:59,212 --> 00:39:02,172 [knocking] 1039 00:39:03,300 --> 00:39:04,591 oh, hey. 1040 00:39:04,676 --> 00:39:05,884 Hold on a second. 1041 00:39:05,969 --> 00:39:07,510 I'm actually shooting something for a tv show, 1042 00:39:07,596 --> 00:39:08,553 so let me kill this. 1043 00:39:08,638 --> 00:39:09,846 ♪ ♪ 1044 00:39:09,931 --> 00:39:14,684 my new big blu 65 power hammer arrived. 1045 00:39:14,770 --> 00:39:17,312 I think the biggest thing I learned from this experience 1046 00:39:17,397 --> 00:39:21,483 is don't challenge two of your really talented friends 1047 00:39:21,568 --> 00:39:25,362 to a two-week competition challenge 1048 00:39:25,447 --> 00:39:27,781 unless your shop is already built. 1049 00:39:27,866 --> 00:39:29,240 [clears throat] 1050 00:39:29,326 --> 00:39:30,867 all right, there's things to do. 1051 00:39:30,952 --> 00:39:32,494 Let's get 'em done. 1052 00:39:32,579 --> 00:39:36,581 I hate that camera--hate, hate. 1053 00:39:36,666 --> 00:39:38,792 The little microphone right here, 1054 00:39:38,877 --> 00:39:42,295 I've lost that little puffball on it so many times 1055 00:39:42,381 --> 00:39:45,382 that I put a zip tie on it to keep it there. 1056 00:39:45,425 --> 00:39:47,675 I have tripped on the cords. 1057 00:39:47,761 --> 00:39:50,303 Oh, lord, just take this camera away, I mean-- 1058 00:39:50,389 --> 00:39:51,846 yeah-yeah-yeah. 1059 00:39:51,932 --> 00:39:53,723 ♪ ♪ 1060 00:39:53,767 --> 00:39:56,393 okay, so-- 1061 00:39:56,478 --> 00:39:58,353 ♪ da, da, da, da ♪ 1062 00:39:58,397 --> 00:40:00,146 let's get some light in here. 1063 00:40:00,232 --> 00:40:03,024 All right, so there she is. She's fitted up. 1064 00:40:03,110 --> 00:40:06,277 There are a number of ways to build a hilt like this, 1065 00:40:06,363 --> 00:40:09,864 and I think I probably chose the hardest. 1066 00:40:09,950 --> 00:40:11,574 But yeah, it's coming together. 1067 00:40:11,660 --> 00:40:12,867 It's almost there, I mean. 1068 00:40:12,953 --> 00:40:15,537 Next I'm going to make what is the covering-- 1069 00:40:15,622 --> 00:40:18,123 guard that sits on the inside of this. 1070 00:40:18,208 --> 00:40:20,792 You ever get a song stuck in your head? 1071 00:40:20,877 --> 00:40:23,878 [laughs] 1072 00:40:25,090 --> 00:40:26,840 I got the theme from "the avengers." 1073 00:40:26,925 --> 00:40:28,216 [laughs] 1074 00:40:28,301 --> 00:40:31,678 [epic adventure music] 1075 00:40:31,763 --> 00:40:34,055 that looks cool. 1076 00:40:34,141 --> 00:40:35,223 See that? 1077 00:40:35,308 --> 00:40:37,350 There she is. Blade's ready. 1078 00:40:37,436 --> 00:40:41,187 Blade's sharp, so I'm going to get j. And ben on the phone. 1079 00:40:41,273 --> 00:40:42,313 Time to hit something. 1080 00:40:42,399 --> 00:40:44,858 ♪ ♪ 1081 00:40:49,948 --> 00:40:51,239 ♪ ♪ 1082 00:40:51,283 --> 00:40:52,949 - all right, guys, been two weeks. 1083 00:40:52,993 --> 00:40:55,243 Ta-da, there she is. - Nice. 1084 00:40:55,328 --> 00:40:56,578 - Wow. - Very nice. 1085 00:40:56,663 --> 00:40:58,788 - J., it's got a lot of protection of the hand 1086 00:40:58,832 --> 00:41:00,457 and the wrist, but at the same time, 1087 00:41:00,500 --> 00:41:01,749 it's not gonna get bound up, 1088 00:41:01,793 --> 00:41:03,710 so I'm pretty sure you'll appreciate that, 1089 00:41:03,795 --> 00:41:08,715 and the blade itself is 1095 and 15n20, 300 layers. 1090 00:41:08,800 --> 00:41:09,966 - It looks great. 1091 00:41:10,010 --> 00:41:11,342 ♪ ♪ 1092 00:41:11,428 --> 00:41:12,760 - for my test, I've got a shield. 1093 00:41:12,846 --> 00:41:15,430 Now, this shield's been with me for, like, 15 years. 1094 00:41:15,474 --> 00:41:17,849 This is a veteran of 1/2 dozen shows, 1095 00:41:17,934 --> 00:41:21,019 and then to follow that up, I'll do a sharpness test 1096 00:41:21,104 --> 00:41:23,480 on this fig branch that I just trimmed off. 1097 00:41:23,523 --> 00:41:26,483 - There you go. - Good luck, brother. 1098 00:41:26,526 --> 00:41:28,276 - All right, so let's see how she does. 1099 00:41:28,361 --> 00:41:29,986 Am I a little nervous? Yeah. 1100 00:41:30,030 --> 00:41:31,362 Every time I swing a blade at something 1101 00:41:31,448 --> 00:41:32,697 that you shouldn't swing a blade at 1102 00:41:32,782 --> 00:41:34,657 I get nervous, but at the same time, 1103 00:41:34,743 --> 00:41:36,493 I'm excited. This is what I live for. 1104 00:41:36,578 --> 00:41:37,744 This is what I love. 1105 00:41:37,829 --> 00:41:44,667 ♪ ♪ 1106 00:41:49,966 --> 00:41:51,883 well, my hand's okay. 1107 00:41:51,968 --> 00:41:53,384 - That's awesome. I like that. 1108 00:41:53,470 --> 00:41:56,179 - I was not expecting him to punch with that basket hilt. 1109 00:41:56,223 --> 00:42:03,186 ♪ ♪ 1110 00:42:04,814 --> 00:42:07,023 [laughter] 1111 00:42:07,067 --> 00:42:09,442 - nice. - She's still straight. 1112 00:42:09,528 --> 00:42:11,152 It's got an edge. 1113 00:42:11,238 --> 00:42:13,029 Like you always say, dave, "it's a cutter." 1114 00:42:13,073 --> 00:42:14,739 - [laughs] she did good. 1115 00:42:14,824 --> 00:42:15,865 She held up. 1116 00:42:15,909 --> 00:42:17,367 - Good job, man. - Nice job. 1117 00:42:17,410 --> 00:42:18,493 - Thanks. 1118 00:42:18,578 --> 00:42:20,161 - We'll all have to do it again sometime. 1119 00:42:20,247 --> 00:42:21,204 - There's one thing I like 1120 00:42:21,289 --> 00:42:22,247 about knifemaking, bladesmithing-- 1121 00:42:22,332 --> 00:42:23,289 there's always new things to try, 1122 00:42:23,375 --> 00:42:24,707 so hell yeah. 1123 00:42:24,751 --> 00:42:26,334 - I'm gonna actually finish building my shop, 1124 00:42:26,419 --> 00:42:28,670 and then we'll do that. 1125 00:42:28,755 --> 00:42:29,879 - I'm going back to work. 1126 00:42:29,965 --> 00:42:32,924 [laughter] 1127 00:42:33,009 --> 00:42:34,801 - is that your better half, j.? 1128 00:42:34,886 --> 00:42:36,886 - Next time they're gonna send a camera crew. 1129 00:42:36,972 --> 00:42:39,973 [laughter] 1130 00:42:40,058 --> 00:42:41,808 - hey, beckie, anything else on your list? 1131 00:42:41,893 --> 00:42:45,562 - We want camera crews and a better [bleep] camera. 1132 00:42:45,647 --> 00:42:46,854 [laughter] 1133 00:42:46,940 --> 00:42:48,356 - so, hey, guys, it was really fun 1134 00:42:48,400 --> 00:42:50,608 seeing your work and seeing you guys 1135 00:42:50,694 --> 00:42:52,026 test that stuff at home. 1136 00:42:52,112 --> 00:42:53,695 I'm looking forward to doing it again 1137 00:42:53,780 --> 00:42:55,405 if you guys are up for it, 1138 00:42:55,448 --> 00:42:57,240 but that was a great, great challenge 1139 00:42:57,284 --> 00:42:59,576 y'all did beautiful work. I'm really impressed. 1140 00:42:59,619 --> 00:43:00,618 You guys take care. 1141 00:43:00,704 --> 00:43:02,328 - Later. - Bye. 1142 00:43:02,414 --> 00:43:07,542 ♪ ♪