1 00:00:05,006 --> 00:00:07,631 [dramatic music] 2 00:00:07,717 --> 00:00:10,926 ♪ ♪ 3 00:00:11,012 --> 00:00:13,178 [rock music] 4 00:00:13,264 --> 00:00:15,973 - my name's justin workman, I'm 39, 5 00:00:16,058 --> 00:00:18,350 and I've been bladesmithing for roughly four years. 6 00:00:18,394 --> 00:00:20,269 The last three months, I've been going through chemo 7 00:00:20,354 --> 00:00:22,312 with the hopes that I would stave off the need 8 00:00:22,398 --> 00:00:24,523 for amputation of my right arm. 9 00:00:24,608 --> 00:00:28,193 I hope this sets an example to anybody that's struggling. 10 00:00:28,279 --> 00:00:31,405 No matter how bad it is, you can still power through. 11 00:00:31,490 --> 00:00:32,740 ♪ ♪ 12 00:00:32,825 --> 00:00:35,868 - my name is dj brelje. I'm 41 years old. 13 00:00:35,953 --> 00:00:39,038 I'm coming from oceanside, california. 14 00:00:39,123 --> 00:00:42,207 The coolest knife I ever made was the knife I forged 15 00:00:42,293 --> 00:00:45,335 to cut my daughter's umbilical cord when she was born. 16 00:00:45,421 --> 00:00:46,628 ♪ ♪ 17 00:00:46,714 --> 00:00:48,047 - my name is doug zegel. 18 00:00:48,132 --> 00:00:49,465 I'm from mount laurel, new jersey. 19 00:00:49,550 --> 00:00:51,508 I'm 33 years old. 20 00:00:51,594 --> 00:00:54,803 My uncle was a blacksmith, so I got to move some metal 21 00:00:54,889 --> 00:00:57,222 with him when I was younger, and I really enjoyed it. 22 00:00:57,308 --> 00:01:00,309 You took something rock-hard like steel, you heat it up, 23 00:01:00,394 --> 00:01:02,227 and it's like play-doh. 24 00:01:02,313 --> 00:01:03,896 I mean, what's cooler than that? 25 00:01:03,939 --> 00:01:05,522 - My name is rob kemensky. 26 00:01:05,608 --> 00:01:07,107 I'm from gaithersburg, maryland. 27 00:01:07,193 --> 00:01:10,069 I've been a police officer for 32 years. 28 00:01:10,112 --> 00:01:12,112 The reason I got into bladesmithing 29 00:01:12,198 --> 00:01:14,239 was because of "forged in fire." 30 00:01:14,325 --> 00:01:18,410 I like the ability to take something that is nothing 31 00:01:18,454 --> 00:01:19,953 and make it into something. 32 00:01:20,039 --> 00:01:22,790 ♪ ♪ 33 00:01:22,875 --> 00:01:25,709 - well, gentlemen, welcome to the forge. 34 00:01:25,795 --> 00:01:28,337 You guys are about to take part in three intense rounds 35 00:01:28,422 --> 00:01:29,713 of forging competition. 36 00:01:29,799 --> 00:01:32,257 At the end of each round, you will present your work 37 00:01:32,343 --> 00:01:34,218 to our panel of expert judges. 38 00:01:34,303 --> 00:01:38,097 Today's judges are abs master smith j. Neilson, 39 00:01:38,182 --> 00:01:40,724 historic weapons re-creation specialist dave baker, 40 00:01:40,810 --> 00:01:43,143 and edged weapons specialist and kali martial artist 41 00:01:43,229 --> 00:01:44,478 doug marcaida. 42 00:01:44,563 --> 00:01:46,313 ♪ ♪ 43 00:01:46,398 --> 00:01:47,898 now, I hope you guys are hungry, 44 00:01:47,983 --> 00:01:49,316 'cause the stakes are high. 45 00:01:49,401 --> 00:01:51,110 Only one of you will be going home the title 46 00:01:51,195 --> 00:01:54,404 of "forged in fire" champion and that check for $10,000. 47 00:01:54,490 --> 00:01:55,614 ♪ ♪ 48 00:01:55,658 --> 00:01:56,949 speaking of hungry, 49 00:01:57,034 --> 00:01:58,408 what's better than walking into a butcher shop 50 00:01:58,452 --> 00:01:59,910 and checking out the meat selection? 51 00:01:59,995 --> 00:02:02,037 Today we're gonna ask you to build a blade 52 00:02:02,123 --> 00:02:03,789 that has been around for thousands of years 53 00:02:03,833 --> 00:02:06,041 and in the hands of butchers around the world. 54 00:02:06,127 --> 00:02:07,793 And that weapon is... 55 00:02:07,878 --> 00:02:09,211 The cleaver. 56 00:02:09,296 --> 00:02:12,840 [sinister music] 57 00:02:12,925 --> 00:02:15,092 - making a cleaver is different in the fact 58 00:02:15,177 --> 00:02:16,885 that you're not just drawing it out, 59 00:02:16,971 --> 00:02:20,097 but you also have to fuller it to widen it as well. 60 00:02:20,182 --> 00:02:21,765 - When you're building your cleavers, 61 00:02:21,851 --> 00:02:23,475 you're gonna need to follow these parameters. 62 00:02:23,519 --> 00:02:25,144 You're gonna have to have an edge 63 00:02:25,229 --> 00:02:26,562 that is between 8 and 9 inches 64 00:02:26,647 --> 00:02:28,105 measured in a straight line 65 00:02:28,190 --> 00:02:30,899 with a base width no less than 3 inches, 66 00:02:30,985 --> 00:02:33,694 and you also must feature a hole near the spine. 67 00:02:33,779 --> 00:02:35,112 ♪ ♪ 68 00:02:35,197 --> 00:02:36,947 now, you're probably wondering what kind of steel 69 00:02:37,032 --> 00:02:38,407 you're gonna be using to make our cleavers, 70 00:02:38,492 --> 00:02:39,700 and that's right here. 71 00:02:39,785 --> 00:02:43,704 ♪ ♪ 72 00:02:43,789 --> 00:02:45,122 you must harvest your materials 73 00:02:45,207 --> 00:02:47,291 from these high-carbon steel meat hooks. 74 00:02:47,376 --> 00:02:48,876 They're all made of w1 steel, 75 00:02:48,961 --> 00:02:50,252 and you can use any method you choose 76 00:02:50,337 --> 00:02:52,462 to build your blades. 77 00:02:52,548 --> 00:02:53,964 Now, in round two of the competition, 78 00:02:54,049 --> 00:02:55,257 you'll be adding handles to your blades, 79 00:02:55,342 --> 00:02:57,467 turning them into fully functional cleavers, 80 00:02:57,553 --> 00:02:58,760 at which point, we'll be testing them 81 00:02:58,846 --> 00:03:00,470 for strength and durability in a bone chop 82 00:03:00,556 --> 00:03:03,724 and for sharpness in a meat and veggie slice. 83 00:03:03,809 --> 00:03:05,684 Now, gentlemen, keep your eyes on the clock 84 00:03:05,769 --> 00:03:08,395 because you only have three hours to complete your work. 85 00:03:08,480 --> 00:03:10,939 And that time starts now. 86 00:03:11,025 --> 00:03:12,983 [rock music] 87 00:03:13,068 --> 00:03:15,152 - one of the things that we have to worry about 88 00:03:15,237 --> 00:03:17,696 is that they have enough steel to make a cleaver. 89 00:03:17,781 --> 00:03:21,909 This is one of those builds where thick helps. 90 00:03:21,994 --> 00:03:24,369 ♪ ♪ 91 00:03:24,413 --> 00:03:26,330 - as soon as I see the meat hooks, 92 00:03:26,415 --> 00:03:30,209 I'm thinking I have to get three handles removed 93 00:03:30,294 --> 00:03:33,712 from the actual hook and flattened out enough 94 00:03:33,756 --> 00:03:37,174 to stack these billets up and get them welded together. 95 00:03:37,259 --> 00:03:38,508 ♪ ♪ 96 00:03:38,594 --> 00:03:41,011 this cleaver's gonna take a lot of metal, 97 00:03:41,096 --> 00:03:43,347 so I have to make sure I have a nice big billet 98 00:03:43,432 --> 00:03:46,850 so I can stretch it out this way and that way. 99 00:03:46,936 --> 00:03:49,394 If I don't start out with a good billet, 100 00:03:49,480 --> 00:03:53,106 then everything I'm doing after that is in jeopardy. 101 00:03:53,192 --> 00:03:54,733 ♪ ♪ 102 00:03:54,777 --> 00:03:56,944 - first thing I'm gonna do is grab the hooks, 103 00:03:57,029 --> 00:04:01,031 chop them off, and get them inside of the forge. 104 00:04:01,116 --> 00:04:03,408 Right now, I think two handles is gonna be enough. 105 00:04:03,494 --> 00:04:04,910 - Dave, you think they need 106 00:04:04,995 --> 00:04:07,204 about three of the hooks to make a single cleaver? 107 00:04:07,248 --> 00:04:09,873 - A minimum of three of the handles. 108 00:04:09,959 --> 00:04:12,167 - I smacked it a couple times with a hammer alone 109 00:04:12,253 --> 00:04:15,295 just to see if it would start compressing. 110 00:04:15,381 --> 00:04:17,714 That allows me to know whether or not 111 00:04:17,800 --> 00:04:21,051 I'm gonna move it in the press. 112 00:04:21,136 --> 00:04:22,386 ♪ ♪ 113 00:04:22,471 --> 00:04:25,681 - I have three hours to knock out a cleaver. 114 00:04:25,766 --> 00:04:27,599 Funny thing is, 115 00:04:27,643 --> 00:04:29,351 I had already done a three-hour challenge 116 00:04:29,436 --> 00:04:32,396 back at home to kind of prep making a cleaver. 117 00:04:32,481 --> 00:04:35,190 I feel like I got a leg up on this one. 118 00:04:35,276 --> 00:04:37,359 I'm gonna be making canister damascus, 119 00:04:37,444 --> 00:04:39,152 so I got to put the liquid paper in there. 120 00:04:39,238 --> 00:04:42,781 - You got justin trying to dry the canister's white out 121 00:04:42,866 --> 00:04:45,909 with the flames of the forge, which is a good way to cook it. 122 00:04:45,995 --> 00:04:47,411 So it doesn't help you peel it. 123 00:04:47,496 --> 00:04:50,956 It'll actually forge weld to the core steel inside. 124 00:04:51,041 --> 00:04:54,001 - Lo and behold, liquid paper catches fire. 125 00:04:54,086 --> 00:04:55,043 ♪ ♪ 126 00:04:55,129 --> 00:04:57,254 after I snuff it out with my glove, 127 00:04:57,339 --> 00:04:58,964 I chop the hooks. 128 00:04:59,049 --> 00:05:00,674 Takes less time to break down. 129 00:05:00,759 --> 00:05:02,259 Mother of god, come on. 130 00:05:02,344 --> 00:05:04,303 Putting all the hooks in there, 131 00:05:04,388 --> 00:05:06,179 still don't have a full canister 132 00:05:06,265 --> 00:05:09,141 and I've already used all my powder. 133 00:05:09,226 --> 00:05:12,853 I'm just praying that I can get it forge welded enough. 134 00:05:12,938 --> 00:05:14,813 ♪ ♪ 135 00:05:14,898 --> 00:05:16,815 - the biggest challenge in making this cleaver 136 00:05:16,900 --> 00:05:19,526 is stretching it out enough 137 00:05:19,611 --> 00:05:20,944 to make the parameters. 138 00:05:21,030 --> 00:05:24,698 My plan is to grab the meat hooks 139 00:05:24,783 --> 00:05:26,908 and cut off the handles, 140 00:05:26,994 --> 00:05:29,328 flatten those out into pieces 141 00:05:29,371 --> 00:05:31,788 that I can stack, forge weld together. 142 00:05:31,874 --> 00:05:33,290 ♪ ♪ 143 00:05:33,375 --> 00:05:35,792 - dj is just drawing that steel out. 144 00:05:35,878 --> 00:05:38,628 Now is a good time to actually start your fullering. 145 00:05:38,714 --> 00:05:40,922 ♪ ♪ 146 00:05:41,008 --> 00:05:44,634 - they aren't as flat as I would like them to be, 147 00:05:44,678 --> 00:05:46,219 but I got to get this going, 148 00:05:46,305 --> 00:05:48,555 so I'm gonna weld them together. 149 00:05:48,640 --> 00:05:49,890 ♪ ♪ 150 00:05:49,975 --> 00:05:52,225 - bladesmiths, we've got two hours 151 00:05:52,311 --> 00:05:54,227 and 30 minutes remaining! 152 00:05:54,313 --> 00:05:55,645 ♪ ♪ 153 00:05:55,731 --> 00:05:57,689 - I want to grind these pieces of steel, 154 00:05:57,733 --> 00:05:59,691 but I can't sit around and let them cool off 155 00:05:59,735 --> 00:06:01,985 by themselves, so I have to get them cool enough 156 00:06:02,071 --> 00:06:04,196 that I can handle them at the grinder. 157 00:06:04,281 --> 00:06:06,323 - What? No! 158 00:06:06,408 --> 00:06:08,367 - So what is that doing to the metal? 159 00:06:08,452 --> 00:06:11,161 - Well, you cool it too fast, and you wind up 160 00:06:11,246 --> 00:06:14,289 with all the grain not really bonding together. 161 00:06:14,375 --> 00:06:16,541 So you wind up with microfractures 162 00:06:16,627 --> 00:06:18,210 all through the metal. 163 00:06:18,253 --> 00:06:20,045 - Welding. 164 00:06:20,130 --> 00:06:23,840 I know that the water tank is a dangerous place to go, 165 00:06:23,884 --> 00:06:25,675 but that clock keeps ticking. 166 00:06:25,761 --> 00:06:28,178 I have to get them welded together, 167 00:06:28,263 --> 00:06:30,680 and I have to get them back in the forge as soon as possible. 168 00:06:30,766 --> 00:06:32,557 ♪ ♪ 169 00:06:32,643 --> 00:06:34,351 - [bleep]. 170 00:06:34,395 --> 00:06:35,977 - Rob's gonna need more metal. 171 00:06:36,063 --> 00:06:37,813 - I'm measuring my cleaver, 172 00:06:37,898 --> 00:06:39,523 and I know it's not gonna meet parameters 173 00:06:39,608 --> 00:06:41,942 unless I come up with a way to add more steel. 174 00:06:42,027 --> 00:06:43,110 ♪ ♪ 175 00:06:43,195 --> 00:06:45,570 so I take the two hooks 176 00:06:45,614 --> 00:06:47,072 that I had cut off, 177 00:06:47,157 --> 00:06:50,492 heat them up, flatten them out a little bit, 178 00:06:50,577 --> 00:06:53,036 clamp them together, weld them, 179 00:06:53,122 --> 00:06:56,123 and hopefully, I'm going to forge weld them 180 00:06:56,208 --> 00:06:57,916 to the top of my cleaver. 181 00:06:57,960 --> 00:06:59,751 I'm gonna try to take a piece of metal 182 00:06:59,795 --> 00:07:01,586 that's 1/4 inch wide 183 00:07:01,672 --> 00:07:04,256 and try to compress other metal on top of it. 184 00:07:04,341 --> 00:07:07,134 It's a shot in the dark, but I have to do something. 185 00:07:07,219 --> 00:07:09,386 ♪ ♪ 186 00:07:09,430 --> 00:07:11,680 - my canister is nice and hot, 187 00:07:11,765 --> 00:07:14,057 and I start to compress. 188 00:07:14,143 --> 00:07:16,226 - Now, that canister could be a little hotter. 189 00:07:16,311 --> 00:07:17,519 - Yeah. 190 00:07:17,563 --> 00:07:19,479 - When you pull a canister out of your forge, 191 00:07:19,565 --> 00:07:22,983 you want that thing to look like a melting stick of butter. 192 00:07:23,068 --> 00:07:24,401 ♪ ♪ 193 00:07:24,486 --> 00:07:28,321 - pretty confident that this sucker is forge welded, 194 00:07:28,407 --> 00:07:30,740 so we're gonna peel back that canister, 195 00:07:30,784 --> 00:07:32,409 and were gonna have a little peek. 196 00:07:32,494 --> 00:07:34,244 ♪ ♪ 197 00:07:34,329 --> 00:07:35,537 oh, [bleep]. 198 00:07:35,622 --> 00:07:37,372 - Oh. 199 00:07:37,458 --> 00:07:38,623 Oh, that's bad. 200 00:07:38,667 --> 00:07:39,791 - [bleep]. 201 00:07:39,877 --> 00:07:40,959 It's not welded. 202 00:07:41,044 --> 00:07:42,752 All right, game plan. 203 00:07:42,838 --> 00:07:45,422 It's time to start over 'cause time is ticking. 204 00:07:45,507 --> 00:07:46,673 - At least justin's 205 00:07:46,758 --> 00:07:48,967 not gonna chase that down the rabbit hole. 206 00:07:49,011 --> 00:07:51,052 Abandoning that billet now is the best thing he can do. 207 00:07:51,138 --> 00:07:52,304 - Yup. 208 00:07:52,389 --> 00:07:54,639 - I have two handles from the meat hooks, 209 00:07:54,683 --> 00:07:56,141 so I'm just gonna flatten them out 210 00:07:56,226 --> 00:07:58,435 and forge weld these together. 211 00:07:58,520 --> 00:08:01,146 ♪ ♪ 212 00:08:01,190 --> 00:08:03,023 - I decided to use big blu 213 00:08:03,108 --> 00:08:06,234 'cause I have experience on a power hammer. 214 00:08:06,320 --> 00:08:07,777 I've never used a press. 215 00:08:07,863 --> 00:08:09,529 ♪ ♪ 216 00:08:09,615 --> 00:08:12,449 - dj's got what looks like a solid billet, 217 00:08:12,534 --> 00:08:14,618 but he's just drawing it out still. 218 00:08:14,703 --> 00:08:17,913 And there's definitely enough length on there already. 219 00:08:17,998 --> 00:08:21,124 - I stretch it out as much as I can, 220 00:08:21,210 --> 00:08:23,335 and I'm just trying to get it wide enough, 221 00:08:23,420 --> 00:08:26,129 so I use the anvil and hammer it by hand. 222 00:08:26,215 --> 00:08:27,464 ♪ ♪ 223 00:08:27,549 --> 00:08:28,673 - look at that. 224 00:08:28,759 --> 00:08:31,635 He's been able to fuller it, widen it out. 225 00:08:31,720 --> 00:08:32,969 ♪ ♪ 226 00:08:33,055 --> 00:08:37,641 - bladesmiths, you guys have two hours remaining! 227 00:08:37,726 --> 00:08:39,976 - All I need to do is chop off the front of this. 228 00:08:40,062 --> 00:08:41,645 I can see if my welds are good, 229 00:08:41,730 --> 00:08:43,813 and from there, I'll just start forging. 230 00:08:43,899 --> 00:08:45,065 ♪ ♪ 231 00:08:45,150 --> 00:08:47,484 luckily, everything starts working out 232 00:08:47,569 --> 00:08:49,486 and I make my way 233 00:08:49,571 --> 00:08:51,321 to seeing that I have a perfectly good billet. 234 00:08:51,365 --> 00:08:52,906 Now it's time to make a knife. 235 00:08:52,991 --> 00:08:54,491 ♪ ♪ 236 00:08:54,576 --> 00:08:56,993 so I keep heating it up, stretching it out, 237 00:08:57,037 --> 00:08:58,995 heating it up, stretching out. 238 00:08:59,039 --> 00:09:00,580 - Looks like doug's been able 239 00:09:00,666 --> 00:09:03,542 to really widen out his metal right now. 240 00:09:03,585 --> 00:09:05,502 - He's got a lot of metal to work with. 241 00:09:05,587 --> 00:09:07,462 ♪ ♪ 242 00:09:07,548 --> 00:09:09,005 - there we go. 243 00:09:09,091 --> 00:09:12,342 This time, I leave my stack in the forge 244 00:09:12,427 --> 00:09:14,594 until it is yellow. 245 00:09:14,680 --> 00:09:17,681 Then I proceed to ask big blu for help. 246 00:09:17,766 --> 00:09:20,642 This is what I should have done all along. 247 00:09:20,727 --> 00:09:21,810 I feel a little bit behind. 248 00:09:21,895 --> 00:09:24,437 I'm glad I wore the brown pants. 249 00:09:24,523 --> 00:09:25,689 ♪ ♪ 250 00:09:25,774 --> 00:09:28,191 - my handle is too far 251 00:09:28,277 --> 00:09:30,193 into the center of the blade. 252 00:09:30,279 --> 00:09:32,862 On a cleaver, the handle's at the top of the blade, 253 00:09:32,948 --> 00:09:36,408 so my plan is to cut the handle off 254 00:09:36,451 --> 00:09:39,369 and then forge weld it right to the blade. 255 00:09:39,454 --> 00:09:41,913 - I think he just cut that handle off. 256 00:09:41,999 --> 00:09:43,415 He's repositioning it. 257 00:09:43,500 --> 00:09:46,293 He's gonna weld it and then forge weld it. 258 00:09:46,378 --> 00:09:48,420 - Any kind of weld at that junction 259 00:09:48,463 --> 00:09:49,838 is not a good idea. 260 00:09:49,923 --> 00:09:52,507 - Creates a weak point. 261 00:09:52,593 --> 00:09:55,719 - I actually make a good forge weld. 262 00:09:55,804 --> 00:09:57,721 ♪ ♪ 263 00:09:57,806 --> 00:09:59,014 [bleep] me. 264 00:09:59,099 --> 00:10:01,308 Unfortunately, in my haste, 265 00:10:01,393 --> 00:10:03,685 I took the handle and I welded it 266 00:10:03,770 --> 00:10:05,395 onto the cutting edge 267 00:10:05,480 --> 00:10:07,606 instead of where I just added 268 00:10:07,691 --> 00:10:10,191 the two pieces of those meat hooks 269 00:10:10,277 --> 00:10:11,359 on top of this cleaver. 270 00:10:11,445 --> 00:10:14,154 - Rob does not look happy right now. 271 00:10:14,239 --> 00:10:15,572 ♪ ♪ 272 00:10:15,657 --> 00:10:17,365 - I've got to cut that handle off again 273 00:10:17,451 --> 00:10:18,908 and I've got to get it on the top. 274 00:10:18,994 --> 00:10:20,118 - That's crazy. 275 00:10:20,203 --> 00:10:22,245 - Just chasing the rabbit down the hole. 276 00:10:22,331 --> 00:10:24,414 - This is digging the hole. - Yeah. 277 00:10:24,499 --> 00:10:27,626 - I don't want to get sent home in the first round. 278 00:10:27,711 --> 00:10:30,045 - You got the ends of those welds that can go wrong. 279 00:10:30,130 --> 00:10:32,464 You've got the middle of those welds that can go wrong. 280 00:10:32,507 --> 00:10:35,467 - You have one hour remaining on the clock. 281 00:10:35,510 --> 00:10:37,093 - Son of a [bleep]. 282 00:10:39,806 --> 00:10:41,264 M not getting good welds. 283 00:10:41,350 --> 00:10:43,642 I had a lot of flux buildup on the blade. 284 00:10:43,685 --> 00:10:45,935 That is making problems welding. 285 00:10:46,021 --> 00:10:48,188 It does cost me some time. 286 00:10:48,273 --> 00:10:50,315 - I love it. It's a franken-cleaver. 287 00:10:50,359 --> 00:10:51,608 [laughter] 288 00:10:51,652 --> 00:10:53,318 [rock music] 289 00:10:53,403 --> 00:10:56,112 - feeling all right because I'm right there. 290 00:10:56,198 --> 00:10:59,574 All I have to do is not screw up the heat treat 291 00:10:59,660 --> 00:11:03,119 and making sure I don't get that infamous fireball 292 00:11:03,205 --> 00:11:04,996 in my already hairless face. 293 00:11:05,040 --> 00:11:08,166 - Oh, there it is. - All right, wait. 294 00:11:08,210 --> 00:11:10,168 We've got one blade quenched. 295 00:11:10,212 --> 00:11:13,922 - I'm praying I don't hear any tings, pops. 296 00:11:14,007 --> 00:11:16,633 - Justin's got a nice warp in this blade there. 297 00:11:16,718 --> 00:11:19,135 - Now I have figure out how to fix this problem. 298 00:11:19,221 --> 00:11:21,346 - This is why it's a good idea to quench early. 299 00:11:21,431 --> 00:11:22,764 - Right. 300 00:11:22,849 --> 00:11:24,683 - So that you can come back and fix some problems. 301 00:11:24,726 --> 00:11:27,352 - I still have a decent amount of mass in it. 302 00:11:27,396 --> 00:11:30,647 Might as well just run the clock out on the grinder. 303 00:11:30,732 --> 00:11:32,816 ♪ ♪ 304 00:11:32,901 --> 00:11:35,026 - I'm pretty confident with the parameters. 305 00:11:35,070 --> 00:11:37,112 I also punched the hole clean 306 00:11:37,197 --> 00:11:39,155 on the first strike. 307 00:11:39,199 --> 00:11:41,157 Now I have to quench it. 308 00:11:41,243 --> 00:11:42,450 ♪ ♪ 309 00:11:42,536 --> 00:11:44,619 - quench now. - There you go. 310 00:11:44,705 --> 00:11:46,579 - Oh. 311 00:11:46,665 --> 00:11:48,373 - It was high, but it wasn't bad. 312 00:11:48,417 --> 00:11:51,376 - Pull it out, and I clamped it in the vise 313 00:11:51,420 --> 00:11:54,295 with a couple pieces of angle iron 314 00:11:54,381 --> 00:11:56,172 just to keep it straight. 315 00:11:56,258 --> 00:11:59,384 It looks pretty good. 316 00:11:59,428 --> 00:12:01,302 - Rob put that blade in the fire 317 00:12:01,388 --> 00:12:03,179 at the temperature he should have quenched at. 318 00:12:03,265 --> 00:12:05,682 - Yeah. - So it's just getting hotter. 319 00:12:05,767 --> 00:12:08,143 - It looks flat. It looks straight. 320 00:12:08,228 --> 00:12:10,687 Five minutes left. I'm gonna quench. 321 00:12:10,772 --> 00:12:11,855 - It's-- - oh, no. 322 00:12:11,940 --> 00:12:14,315 - Whoa! - Holy cow! 323 00:12:14,401 --> 00:12:15,817 - That was hot. 324 00:12:15,902 --> 00:12:17,986 - In the back of my mind, I'm gonna pull it out 325 00:12:18,071 --> 00:12:20,655 and the only thing I'm gonna have is the handle. 326 00:12:20,741 --> 00:12:22,615 Thankfully, it did come out in one piece. 327 00:12:22,701 --> 00:12:24,951 I'm not happy with how it looks, 328 00:12:25,036 --> 00:12:26,870 but it's definitely hard. 329 00:12:26,955 --> 00:12:28,705 ♪ ♪ 330 00:12:28,790 --> 00:12:31,875 - doug is in the grinder, and can he get his blade 331 00:12:31,960 --> 00:12:32,959 up to temperature 332 00:12:33,003 --> 00:12:34,669 with less than five minutes to go? 333 00:12:34,755 --> 00:12:36,171 - It's gonna take him two or three minutes 334 00:12:36,256 --> 00:12:38,214 to get that up to temp. - Exactly. 335 00:12:38,300 --> 00:12:40,049 [tense music] 336 00:12:40,135 --> 00:12:42,260 - I may have gotten a little bit too confident. 337 00:12:42,304 --> 00:12:44,179 I spent too much time on the grinder. 338 00:12:44,264 --> 00:12:46,222 Now I got to get this billet heated up. 339 00:12:46,308 --> 00:12:49,184 - Gentlemen, you got two minutes on the clock! 340 00:12:49,269 --> 00:12:51,227 - It's do-or-die. 341 00:12:51,313 --> 00:12:52,479 - Just put it in there. 342 00:12:52,564 --> 00:12:54,355 - Ah, the old one-minute quench. 343 00:12:54,441 --> 00:12:55,565 - Gonna be a 30-second quench. 344 00:12:55,650 --> 00:12:56,775 - It's gonna be a 30-second quench, yeah. 345 00:12:56,860 --> 00:12:58,067 - Oh, come on. 346 00:12:58,153 --> 00:13:00,612 - Oh, no, no, no, no. Okay. 347 00:13:00,655 --> 00:13:03,656 ♪ ♪ 348 00:13:03,742 --> 00:13:05,909 - he's in there. - All right, finally. 349 00:13:05,994 --> 00:13:07,368 - Leave it in there. 350 00:13:07,454 --> 00:13:11,414 - Ten, nine, eight, seven, 351 00:13:11,458 --> 00:13:14,793 six, five, four, 352 00:13:14,878 --> 00:13:18,254 three, two, one. 353 00:13:18,298 --> 00:13:19,506 Gentlemen, turn off your machines. 354 00:13:19,591 --> 00:13:22,467 Put down your tools. This round is over. 355 00:13:22,511 --> 00:13:24,427 - Whoo. 356 00:13:24,513 --> 00:13:26,095 - [exhales heavily] 357 00:13:26,181 --> 00:13:28,139 at this point, it looks good, 358 00:13:28,183 --> 00:13:30,475 but I have to hope that there's no other issues 359 00:13:30,519 --> 00:13:32,811 that I didn't see in this blade. 360 00:13:32,896 --> 00:13:35,939 I didn't even look and see if it's straight. 361 00:13:36,024 --> 00:13:38,775 ♪ ♪ 362 00:13:38,860 --> 00:13:40,109 - all right, gentlemen, in round one, 363 00:13:40,153 --> 00:13:41,236 you guys took your meat hooks 364 00:13:41,321 --> 00:13:42,987 and you turned them into cleavers, 365 00:13:43,073 --> 00:13:45,323 but it is time for the judges to make their critique, 366 00:13:45,408 --> 00:13:46,658 so let's get into it. 367 00:13:46,743 --> 00:13:47,826 Justin, please present your work. 368 00:13:47,869 --> 00:13:49,744 ♪ ♪ 369 00:13:49,830 --> 00:13:52,622 - all right, justin, first of all, aesthetically, 370 00:13:52,666 --> 00:13:55,291 I'm not exactly thrilled with this handle kicking up. 371 00:13:55,377 --> 00:13:58,753 You do have a pretty good warp on here. 372 00:13:58,839 --> 00:14:00,547 It's not laying flat on the table. 373 00:14:00,632 --> 00:14:01,965 Big thing I noticed, though, is, 374 00:14:02,050 --> 00:14:03,675 I noticed the blue right in here, 375 00:14:03,718 --> 00:14:05,009 and yeah, you can hear, 376 00:14:05,053 --> 00:14:06,427 I can get my finger in there 377 00:14:06,513 --> 00:14:07,679 and move that thin steel around. 378 00:14:07,722 --> 00:14:10,890 But you presented us a blade. Good job. 379 00:14:10,976 --> 00:14:12,934 - Thank you. - All right, dj, you ready? 380 00:14:13,019 --> 00:14:14,310 Please present your work. 381 00:14:14,396 --> 00:14:16,521 ♪ ♪ 382 00:14:16,565 --> 00:14:19,190 - all right, deej, let's talk about your cleaver here. 383 00:14:19,234 --> 00:14:20,984 There are no delaminations. 384 00:14:21,027 --> 00:14:22,527 Overall, it seems that 385 00:14:22,571 --> 00:14:24,487 you have a solid piece of steel. 386 00:14:24,573 --> 00:14:28,324 Moving forward, it's more about refining the shape 387 00:14:28,410 --> 00:14:32,036 that you have, but I think you did a good job. 388 00:14:32,080 --> 00:14:33,121 - Thank you. 389 00:14:33,206 --> 00:14:34,122 - All right, doug, you're up. 390 00:14:34,207 --> 00:14:35,331 Come present your blade. 391 00:14:35,417 --> 00:14:37,333 ♪ ♪ 392 00:14:37,419 --> 00:14:39,294 - all right, doug, this is good-looking steel. 393 00:14:39,379 --> 00:14:40,879 As far as the cleaver shape goes, 394 00:14:40,964 --> 00:14:42,213 classic cleaver shape. 395 00:14:42,257 --> 00:14:43,965 [chuckles] you pretty much lucked out 396 00:14:44,050 --> 00:14:46,259 on that 45-second quench, 397 00:14:46,344 --> 00:14:48,177 that you didn't pick up a warp. - Yeah. 398 00:14:48,263 --> 00:14:49,846 - Your edge is nice and straight 399 00:14:49,931 --> 00:14:53,057 and there's a slight bend back here, but nice job. 400 00:14:53,143 --> 00:14:54,475 - Thank you. 401 00:14:54,561 --> 00:14:56,060 - All right, last but not least, rob, 402 00:14:56,104 --> 00:14:57,186 please present your work. 403 00:14:57,272 --> 00:14:58,897 ♪ ♪ 404 00:14:58,940 --> 00:15:01,149 - all right, rob, trying to get 405 00:15:01,234 --> 00:15:03,735 a 1/4 inch weld on the edge is really tough. 406 00:15:03,778 --> 00:15:05,904 There are sections where, right here, 407 00:15:05,947 --> 00:15:07,822 I can actually see through the blade. 408 00:15:07,908 --> 00:15:10,366 I think you had a really good idea 409 00:15:10,452 --> 00:15:12,577 swapping the handle, 410 00:15:12,621 --> 00:15:13,870 making this the edge 411 00:15:13,955 --> 00:15:15,747 since there's a lot more solid steel down here. 412 00:15:15,832 --> 00:15:19,208 But you kept finding ways to work around the issues, 413 00:15:19,294 --> 00:15:20,543 and I commend that. 414 00:15:20,629 --> 00:15:22,712 It's here, so good job. - Thank you. 415 00:15:22,797 --> 00:15:24,172 - All right, gentlemen, 416 00:15:24,257 --> 00:15:26,382 well, you all brought us some meaty cleavers, 417 00:15:26,468 --> 00:15:27,842 but the judges made a decision, 418 00:15:27,928 --> 00:15:29,510 and only three of you will be moving forward 419 00:15:29,596 --> 00:15:31,387 into round two of the competition. 420 00:15:31,431 --> 00:15:33,222 The bladesmith heading home is... 421 00:15:33,308 --> 00:15:36,434 ♪ ♪ 422 00:15:36,519 --> 00:15:37,727 rob. 423 00:15:37,812 --> 00:15:39,062 You fought hard and you brought us a blade, 424 00:15:39,147 --> 00:15:40,688 which doesn't always happen. 425 00:15:40,774 --> 00:15:42,357 J. Neilson is gonna be telling why you're going home. 426 00:15:42,442 --> 00:15:45,610 - Rob, you never quit, and that's fantastic to see. 427 00:15:45,654 --> 00:15:47,487 But with the cleaver you presented us, 428 00:15:47,572 --> 00:15:48,947 there's multiple seams in there 429 00:15:49,032 --> 00:15:50,740 and at least three places in the blade 430 00:15:50,825 --> 00:15:52,617 that we could see light through it. 431 00:15:52,702 --> 00:15:54,577 That makes us question the structural integrity 432 00:15:54,663 --> 00:15:56,412 of your blade, and that's why you're going home. 433 00:15:56,498 --> 00:15:58,247 - I understand 100%. - All right, rob, 434 00:15:58,291 --> 00:16:00,083 please surrender your weapon. 435 00:16:00,168 --> 00:16:01,459 ♪ ♪ 436 00:16:01,503 --> 00:16:03,753 - what the judges had to say about my blade 437 00:16:03,838 --> 00:16:05,630 was certainly what I was thinking. 438 00:16:05,715 --> 00:16:07,423 There's never a time when you can hold a blade up 439 00:16:07,467 --> 00:16:10,426 and see cracks through it that it's gonna be any good. 440 00:16:10,512 --> 00:16:12,929 I'm happy that it got to the judges' table. 441 00:16:13,014 --> 00:16:14,180 It looked like a cleaver, 442 00:16:14,265 --> 00:16:16,474 which is what it was supposed to be. 443 00:16:16,518 --> 00:16:18,017 - All right, gentlemen, congratulations. 444 00:16:18,103 --> 00:16:19,727 The three of you are moving forward 445 00:16:19,813 --> 00:16:21,229 into round two of the competition, 446 00:16:21,314 --> 00:16:22,605 where you will add handles to your blades, 447 00:16:22,691 --> 00:16:24,732 turning them into fully functioning cleavers. 448 00:16:24,818 --> 00:16:27,151 Next to me, you see three butcher blocks. 449 00:16:27,195 --> 00:16:28,611 That, along with pin stock, 450 00:16:28,697 --> 00:16:30,488 is the only material that you can use for your handles. 451 00:16:30,573 --> 00:16:32,573 Now, after you guys finish your handle work, 452 00:16:32,659 --> 00:16:35,243 we'll be testing for strength and durability in a bone chop 453 00:16:35,328 --> 00:16:38,246 and for edge retention in a meat and veggie slice. 454 00:16:38,331 --> 00:16:40,123 Now, remember, you only have two hours on the clock 455 00:16:40,166 --> 00:16:41,666 for this competition. 456 00:16:41,710 --> 00:16:43,626 And that time starts now. 457 00:16:43,670 --> 00:16:46,421 [rock music] 458 00:16:46,506 --> 00:16:47,547 before butcher block, 459 00:16:47,632 --> 00:16:49,632 they need to fix all these problems. 460 00:16:49,718 --> 00:16:51,342 - Unfortunately, there's so much going on 461 00:16:51,386 --> 00:16:52,844 in justin's head right now. 462 00:16:52,887 --> 00:16:55,263 - Oh, he definitely came in behind the other two smiths. 463 00:16:55,348 --> 00:16:56,764 - Going into round two, 464 00:16:56,850 --> 00:16:58,641 I have three critiques: 465 00:16:58,727 --> 00:17:01,310 The upswept handle, the delam, 466 00:17:01,396 --> 00:17:04,355 and the good old banana peel-- the warp. 467 00:17:04,399 --> 00:17:07,150 I'm going to address the handle first. 468 00:17:07,235 --> 00:17:10,278 So I decide to go with a three-piece hidden tang. 469 00:17:10,363 --> 00:17:13,156 By doing this, it allows me to cut out a couple steps 470 00:17:13,241 --> 00:17:15,324 trying to pin the handle together. 471 00:17:15,410 --> 00:17:17,118 So far, so good. 472 00:17:17,203 --> 00:17:18,995 This is definitely more about just getting it done 473 00:17:19,080 --> 00:17:21,706 and turning something in than worrying about perfection. 474 00:17:21,750 --> 00:17:26,252 Now I grab the butcher block and cut my three pieces 475 00:17:26,337 --> 00:17:29,005 and start grinding the center block. 476 00:17:29,090 --> 00:17:30,423 [bleep]. Hey-oh. 477 00:17:30,508 --> 00:17:32,216 The grinder rips the block 478 00:17:32,260 --> 00:17:36,012 and shoots it into that nasty water bucket. 479 00:17:36,097 --> 00:17:37,221 Whoops. 480 00:17:37,265 --> 00:17:39,390 - My plan for the handle 481 00:17:39,434 --> 00:17:42,643 is to cut two identical scales 482 00:17:42,729 --> 00:17:44,395 and pin them together. 483 00:17:44,439 --> 00:17:46,230 I'm putting the holes in the tang, 484 00:17:46,274 --> 00:17:48,191 so I went straight to the torch 485 00:17:48,276 --> 00:17:50,526 to just cut a huge clearance hole. 486 00:17:50,612 --> 00:17:52,695 - That's what dj's doing is blowing pin holes. 487 00:17:52,781 --> 00:17:54,572 - Drilling is prettier, 488 00:17:54,616 --> 00:17:57,200 but cutting with a torch is faster. 489 00:17:57,285 --> 00:17:59,410 I'm just trying to get it done. 490 00:17:59,454 --> 00:18:00,620 I'm pretty confident. 491 00:18:00,705 --> 00:18:01,579 I feel like I'm gonna finish the blade 492 00:18:01,664 --> 00:18:04,040 and have something to turn in. 493 00:18:04,125 --> 00:18:05,750 - After I approach the handle, 494 00:18:05,835 --> 00:18:08,544 I'm now gonna be dealing with that major warp. 495 00:18:08,630 --> 00:18:10,379 So I build a jig, 496 00:18:10,465 --> 00:18:12,924 get it set up, and heat up the spine. 497 00:18:12,967 --> 00:18:14,717 ♪ ♪ 498 00:18:14,803 --> 00:18:18,012 my genius self, I'm heating up the wrong side. 499 00:18:18,098 --> 00:18:19,555 [bleep]. 500 00:18:19,641 --> 00:18:21,390 Instead of taking the warp out, 501 00:18:21,434 --> 00:18:23,434 I'm putting a bigger warp in. 502 00:18:23,520 --> 00:18:25,853 That is not working. 503 00:18:25,939 --> 00:18:27,438 [bleep]. 504 00:18:27,482 --> 00:18:31,109 So now I have to reheat the blade on the proper side, 505 00:18:31,194 --> 00:18:33,653 and I pray that I have it hot enough 506 00:18:33,738 --> 00:18:35,530 because if it's not hot enough, 507 00:18:35,615 --> 00:18:37,824 I am going to snap this blade. 508 00:18:37,909 --> 00:18:40,243 Please don't break. Please don't break. 509 00:18:40,328 --> 00:18:41,619 ♪ ♪ 510 00:18:45,375 --> 00:18:48,084 this could definitely send me home. 511 00:18:48,169 --> 00:18:50,169 And lo and behold, it does not snap. 512 00:18:50,255 --> 00:18:51,796 That's gonna have to do. 513 00:18:51,881 --> 00:18:53,631 I've got this thing pretty straight, 514 00:18:53,716 --> 00:18:56,050 so now we can move on to bigger and better things. 515 00:18:56,136 --> 00:18:57,552 ♪ ♪ 516 00:18:57,637 --> 00:18:59,470 - I know I'm a little bit behind my competitors, 517 00:18:59,514 --> 00:19:01,430 but right now, I just have to focus on what I need to do. 518 00:19:01,516 --> 00:19:03,432 Getting these holes drilled in the tang 519 00:19:03,476 --> 00:19:05,143 is one of my major concerns, 520 00:19:05,228 --> 00:19:08,229 so if I can get that done, I'm in good shape. 521 00:19:08,314 --> 00:19:09,522 I'm at the drill press, 522 00:19:09,607 --> 00:19:12,859 and I purposely left my handle unquenched. 523 00:19:12,944 --> 00:19:14,986 I wanted that metal to be a little bit softer 524 00:19:15,029 --> 00:19:17,155 so that I had a better chance of drilling through it. 525 00:19:17,198 --> 00:19:18,823 ♪ ♪ 526 00:19:18,867 --> 00:19:20,992 I got the holes drilled very easily, so now 527 00:19:21,035 --> 00:19:23,911 I just have to get the pieces of the butcher block cut, 528 00:19:23,997 --> 00:19:26,247 start getting them assembled, epoxied on, 529 00:19:26,332 --> 00:19:27,915 and then start shaping. 530 00:19:28,001 --> 00:19:30,042 - All right, gentlemen, you guys are halfway through. 531 00:19:30,128 --> 00:19:32,670 There's one hour left on the clock. 532 00:19:32,714 --> 00:19:36,591 - I'm going to put the handle on and refine the shape of it. 533 00:19:36,676 --> 00:19:38,176 ♪ ♪ 534 00:19:38,219 --> 00:19:41,345 I had extra time, and you got to do something, 535 00:19:41,389 --> 00:19:43,556 so I try and decorate the handle. 536 00:19:43,641 --> 00:19:45,308 I started drawing, you know, 537 00:19:45,393 --> 00:19:47,185 things I thought about a chef would use 538 00:19:47,270 --> 00:19:49,604 like a pot, fork, a spoon. 539 00:19:49,689 --> 00:19:51,480 Give it more character. 540 00:19:51,566 --> 00:19:52,982 I feel like a caveman when I'm doing it, 541 00:19:53,067 --> 00:19:54,859 and it's a lot of fun. 542 00:19:54,903 --> 00:19:57,528 I'm trying to make something that has soul 543 00:19:57,572 --> 00:20:00,031 and something you can't get at a store. 544 00:20:00,074 --> 00:20:02,575 'cause I'm human being, not a machine. 545 00:20:02,660 --> 00:20:03,910 - Right now, I need to focus 546 00:20:03,995 --> 00:20:05,786 on the handle being comfortable. 547 00:20:05,872 --> 00:20:08,206 The blade has to interact with the target, 548 00:20:08,249 --> 00:20:10,208 but the handle has to interact with the user, 549 00:20:10,251 --> 00:20:12,543 so I want to make sure I balance my time evenly 550 00:20:12,587 --> 00:20:13,794 between those two things. 551 00:20:13,880 --> 00:20:16,380 ♪ ♪ 552 00:20:16,466 --> 00:20:17,798 - I'd really like to see doug 553 00:20:17,884 --> 00:20:19,217 knock those edges off that handle. 554 00:20:19,260 --> 00:20:21,052 - I was just gonna say the same thing. 555 00:20:21,137 --> 00:20:22,386 That's gonna hurt when you're swinging it. 556 00:20:22,430 --> 00:20:23,763 - I've got my handle roughed out. 557 00:20:23,848 --> 00:20:26,724 From now, it's just about the details. 558 00:20:26,809 --> 00:20:29,143 - All right, bladesmiths, you got 20 minutes left. 559 00:20:29,229 --> 00:20:30,478 ♪ ♪ 560 00:20:30,563 --> 00:20:32,605 - so the last thing I need to address 561 00:20:32,690 --> 00:20:34,774 is that delam in the center. 562 00:20:34,859 --> 00:20:36,400 - Justin's got a big, old hole. 563 00:20:36,444 --> 00:20:38,110 - Justin could've got an occlusion. 564 00:20:38,196 --> 00:20:40,112 First thing that justin's got to do is 565 00:20:40,198 --> 00:20:41,447 just clean all of that out. 566 00:20:41,532 --> 00:20:42,740 - I'm gonna go to the grinder. 567 00:20:42,825 --> 00:20:44,367 I put the contact wheel in, 568 00:20:44,452 --> 00:20:46,160 start grinding, 569 00:20:46,246 --> 00:20:48,204 and I realize 570 00:20:48,248 --> 00:20:50,414 it's bigger than I thought it was. 571 00:20:50,458 --> 00:20:51,916 Oh, [bleep]. 572 00:20:52,001 --> 00:20:55,670 A little bit of concern is hitting me. 573 00:20:55,755 --> 00:20:56,963 Welding. 574 00:20:57,006 --> 00:20:59,924 The only logical solution that I can think of 575 00:20:59,968 --> 00:21:03,803 is grab the welder, fill the hole, grind it clean. 576 00:21:03,888 --> 00:21:06,597 Right now, I feel this is the only option to take. 577 00:21:06,683 --> 00:21:08,641 - If that blue doesn't go all the way to the edge, 578 00:21:08,726 --> 00:21:09,976 just seal that inside. 579 00:21:10,061 --> 00:21:11,769 - Almost there. 580 00:21:11,813 --> 00:21:14,939 Finally, we have solid steel. 581 00:21:14,983 --> 00:21:17,275 So I just tried to just to pack it in there. 582 00:21:17,360 --> 00:21:19,485 And now I'm just trying to grind it flat, clean her up. 583 00:21:19,570 --> 00:21:21,195 - 10 minutes remaining on the clock. 584 00:21:21,281 --> 00:21:23,406 - So now that I'm in a good place with my handle, 585 00:21:23,491 --> 00:21:25,241 I just want to refine that edge. 586 00:21:25,285 --> 00:21:28,786 I want that edge to be strong because it's meant to chop. 587 00:21:28,830 --> 00:21:30,579 ♪ ♪ 588 00:21:30,623 --> 00:21:32,623 so I work, and I just refine it 589 00:21:32,709 --> 00:21:34,125 on the stone a little bit 590 00:21:34,168 --> 00:21:35,960 it's sharp, and all of a sudden, 591 00:21:36,004 --> 00:21:39,463 I realized this nice wooden handle that I made, 592 00:21:39,507 --> 00:21:42,967 it's covered in sawdust and grit from the knife. 593 00:21:43,011 --> 00:21:44,969 If I have a little bit more time to sand, 594 00:21:45,054 --> 00:21:46,512 I can make this thing look beautiful, 595 00:21:46,597 --> 00:21:49,557 but right now, I got to just clean it up as best as I can. 596 00:21:49,642 --> 00:21:51,684 - Five, four, 597 00:21:51,769 --> 00:21:54,228 three, two, one. 598 00:21:54,314 --> 00:21:56,314 Put down your blades. Put down your tools. 599 00:21:56,399 --> 00:21:58,024 This round is over. 600 00:21:58,109 --> 00:21:59,483 - Right now, I'm feeling very confident, 601 00:21:59,527 --> 00:22:01,485 but I think all three of us did great job. 602 00:22:01,571 --> 00:22:04,322 It's gonna come down to how our blades deal 603 00:22:04,365 --> 00:22:05,990 with the challenges in the testing. 604 00:22:06,034 --> 00:22:07,742 ♪ ♪ 605 00:22:07,827 --> 00:22:10,453 - all right, bladesmiths, welcome to our strength test-- 606 00:22:10,538 --> 00:22:12,121 our bone chop. 607 00:22:12,206 --> 00:22:13,622 I'm gonna take your cleavers 608 00:22:13,708 --> 00:22:15,708 and smash through these series of bones. 609 00:22:15,793 --> 00:22:16,792 What your blades do to the bones 610 00:22:16,878 --> 00:22:18,669 is pretty much irrelevant. 611 00:22:18,713 --> 00:22:20,463 I want to see what the bones are gonna do to your blades. 612 00:22:20,548 --> 00:22:22,173 All right, dj, you look excited. 613 00:22:22,216 --> 00:22:25,343 - I am. - All right, let's go do this. 614 00:22:25,428 --> 00:22:27,011 [laughter] 615 00:22:27,055 --> 00:22:30,514 - I'm excited to see a legend test my blade 616 00:22:30,558 --> 00:22:31,891 on a big-ass bone. 617 00:22:31,976 --> 00:22:34,435 I'm not worried about it chipping, but it could break. 618 00:22:34,520 --> 00:22:35,436 The bone's hard. 619 00:22:35,521 --> 00:22:37,897 ♪ ♪ 620 00:22:37,982 --> 00:22:40,775 - [grunting] 621 00:22:40,860 --> 00:22:46,864 ♪ ♪ 622 00:22:46,908 --> 00:22:48,491 - [chuckles] 623 00:22:48,576 --> 00:22:49,700 - all right, dj. Nice job. 624 00:22:49,744 --> 00:22:51,035 The edge held up just fine. 625 00:22:51,120 --> 00:22:52,119 It felt comfortable in a hand. 626 00:22:52,205 --> 00:22:53,788 A little bit square on the bottom, 627 00:22:53,873 --> 00:22:55,039 but everything's tight. 628 00:22:55,124 --> 00:22:56,707 Nicely done. - Thank you. 629 00:22:56,751 --> 00:22:57,750 - All right, doug, you're up. 630 00:22:57,835 --> 00:22:59,168 How you feeling? - Feeling pretty good. 631 00:22:59,253 --> 00:23:02,171 Have at it. - All right, let's do it. 632 00:23:02,256 --> 00:23:03,547 - All I'm thinking is, 633 00:23:03,591 --> 00:23:06,675 what animal did that giant bone come out of? 634 00:23:06,719 --> 00:23:09,470 I'm just hoping that it doesn't roll the edge of my blade. 635 00:23:09,555 --> 00:23:12,598 ♪ ♪ 636 00:23:12,683 --> 00:23:15,643 - [grunting] 637 00:23:15,728 --> 00:23:22,733 ♪ ♪ 638 00:23:26,030 --> 00:23:28,364 all right, doug, you survived the bone chop. 639 00:23:28,408 --> 00:23:29,949 Good job. The biggest concern I have 640 00:23:30,034 --> 00:23:32,576 is the thickness of your handle right here. 641 00:23:32,620 --> 00:23:35,162 A little bit short, but there's no gapping. 642 00:23:35,248 --> 00:23:37,373 Everything's tight, and your edge is still sharp. 643 00:23:37,458 --> 00:23:39,834 Good job. - Thank you. 644 00:23:39,919 --> 00:23:41,585 - Justin, you're up. How you feeling? 645 00:23:41,629 --> 00:23:43,254 - Go to town. - That's not a problem. 646 00:23:43,297 --> 00:23:44,922 ♪ ♪ 647 00:23:44,966 --> 00:23:47,425 - going into round two testing, I am terrified. 648 00:23:47,468 --> 00:23:49,427 I don't know if I fixed the delam, 649 00:23:49,470 --> 00:23:52,430 and I look over there, and there's a big-ass bone. 650 00:23:52,473 --> 00:23:55,015 My heart sinks to my stomach. 651 00:23:55,101 --> 00:23:57,768 ♪ ♪ 652 00:24:00,356 --> 00:24:02,440 - [grunting] 653 00:24:02,483 --> 00:24:09,447 ♪ ♪ 654 00:24:12,160 --> 00:24:13,742 all right, justin, good job. You survived. 655 00:24:13,828 --> 00:24:16,162 I was a little concerned with the gapping 656 00:24:16,247 --> 00:24:18,664 right here at the shoulders, but it held up just fine. 657 00:24:18,749 --> 00:24:20,958 You might've had a hole on the side of your blade, 658 00:24:21,043 --> 00:24:22,418 but there's nothing wrong with your edge. 659 00:24:22,503 --> 00:24:23,961 Good job. - Thank you. 660 00:24:24,005 --> 00:24:25,421 ♪ ♪ 661 00:24:25,506 --> 00:24:27,214 - all right, bladesmiths, 662 00:24:27,300 --> 00:24:28,674 j. Had a bone to pick with your cleavers, 663 00:24:28,759 --> 00:24:31,469 now it's time to find out how sharp your cleavers are. 664 00:24:31,512 --> 00:24:32,845 This is the sharpness test-- 665 00:24:32,930 --> 00:24:35,139 the meat and vegetable slice. 666 00:24:35,183 --> 00:24:37,975 Now, unlike the strength test, this is all about 667 00:24:38,019 --> 00:24:41,645 how well your cleavers cut the meat and vegetables. 668 00:24:41,689 --> 00:24:43,147 All right, dj, your turn. Are you ready? 669 00:24:43,232 --> 00:24:45,149 - Does a one-legged duck swim in a circle? 670 00:24:45,234 --> 00:24:46,859 - Uh, quack, quack? - [laughs] 671 00:24:46,944 --> 00:24:47,943 - let's do this. 672 00:24:48,029 --> 00:24:55,159 ♪ ♪ 673 00:25:10,927 --> 00:25:12,134 all right, dj, 674 00:25:12,220 --> 00:25:13,469 let's talk about your cleaver here. 675 00:25:13,554 --> 00:25:15,971 There are sharp edges at the top here, 676 00:25:16,015 --> 00:25:18,682 but not as sharp in the middle part. 677 00:25:18,768 --> 00:25:19,808 When we cut the meat, 678 00:25:19,852 --> 00:25:21,310 it didn't cut all the way through, 679 00:25:21,395 --> 00:25:24,522 but overall, it will cut. 680 00:25:24,565 --> 00:25:25,856 - Thanks. 681 00:25:25,900 --> 00:25:27,650 - All right, doug-- great name. 682 00:25:27,735 --> 00:25:29,860 Are you ready? - Absolutely, ready to go. 683 00:25:29,904 --> 00:25:36,992 ♪ ♪ 684 00:25:55,263 --> 00:25:56,387 - all right, doug, 685 00:25:56,472 --> 00:25:59,265 on the meat slice, it chopped, 686 00:25:59,350 --> 00:26:01,225 but it's not a clean cut all the way through. 687 00:26:01,269 --> 00:26:04,228 Now, on the produce side, it pretty much cut everything. 688 00:26:04,272 --> 00:26:07,231 Overall, sir, your cleaver will cut. 689 00:26:07,275 --> 00:26:08,399 - Thanks. - Justin, you're up. 690 00:26:08,484 --> 00:26:10,067 You ready for this? - Let it rip. 691 00:26:10,152 --> 00:26:11,026 - All right. 692 00:26:11,112 --> 00:26:18,242 ♪ ♪ 693 00:26:31,632 --> 00:26:33,549 - all right, justin, let's talk about your cleaver here. 694 00:26:33,634 --> 00:26:36,260 With the cuts over here, plenty sharp. 695 00:26:36,345 --> 00:26:38,304 Everything it cut through, except for the melon, 696 00:26:38,389 --> 00:26:40,806 but overall, sir, your cleaver, it will cut. 697 00:26:40,891 --> 00:26:42,391 - Thank you. 698 00:26:42,476 --> 00:26:44,018 - All right, gentlemen, 699 00:26:44,103 --> 00:26:46,395 you all met parameters and you all tested well, 700 00:26:46,439 --> 00:26:48,230 but unfortunately, only two of you will be moving forward 701 00:26:48,274 --> 00:26:50,107 into round three of the competition. 702 00:26:50,151 --> 00:26:51,567 The judges have made their decision, 703 00:26:51,652 --> 00:26:53,736 and the bladesmith not moving forward is... 704 00:26:53,821 --> 00:26:55,613 ♪ ♪ 705 00:26:55,698 --> 00:26:58,157 dj. And doug's gonna tell you why. 706 00:26:58,242 --> 00:27:01,243 - Dj, it came down to the sharpness test. 707 00:27:01,329 --> 00:27:03,787 Your blade has an obtuse edge. 708 00:27:03,873 --> 00:27:06,332 That, coupled with dulling from the strength test-- 709 00:27:06,417 --> 00:27:08,959 well, the potato getting hung up on it says it all. 710 00:27:09,003 --> 00:27:10,461 For that reason, we're sending you home. 711 00:27:10,546 --> 00:27:12,671 - Now dj, unfortunately your time in the forge has ended. 712 00:27:12,757 --> 00:27:14,757 I'm gonna have to ask you to please leave the floor. 713 00:27:14,842 --> 00:27:16,634 - All right. Thanks for the opportunity. 714 00:27:16,677 --> 00:27:18,135 - Well done. 715 00:27:18,179 --> 00:27:20,471 - I would've liked to have done things better. 716 00:27:20,514 --> 00:27:22,973 I would've tried to slow down. 717 00:27:23,017 --> 00:27:25,267 I still got a lot to learn about making knives, 718 00:27:25,353 --> 00:27:27,269 but I had a good time. 719 00:27:27,355 --> 00:27:28,479 ♪ ♪ 720 00:27:28,564 --> 00:27:30,314 - justin, doug, congratulations. 721 00:27:30,399 --> 00:27:32,232 You guys made it past round one and two, 722 00:27:32,318 --> 00:27:34,693 and now it's just between the two of you for the title 723 00:27:34,779 --> 00:27:37,279 of "forged in fire" champion and a check for $10,000. 724 00:27:37,323 --> 00:27:38,739 In round three of the competition, 725 00:27:38,783 --> 00:27:40,699 we're gonna send you home to make another culinary tool, 726 00:27:40,785 --> 00:27:41,950 but this one's quite a bit bigger 727 00:27:42,036 --> 00:27:42,993 than anything you've seen. 728 00:27:43,079 --> 00:27:44,453 And that tool is... 729 00:27:44,538 --> 00:27:46,330 ♪ ♪ 730 00:27:46,415 --> 00:27:47,998 the maguro bocho. 731 00:27:48,042 --> 00:27:50,125 - [exhales] 732 00:27:50,169 --> 00:27:51,585 - also known as the tuna sword, 733 00:27:51,671 --> 00:27:54,004 the maguro bocho is a specialized cutting tool 734 00:27:54,048 --> 00:27:56,173 designed to fillet massive bluefin tuna. 735 00:27:56,258 --> 00:27:59,009 This impressive blade is not your average kitchen cutlery. 736 00:27:59,095 --> 00:28:01,053 With a total length up to three feet long, 737 00:28:01,138 --> 00:28:03,472 these culinary swords are often hand-forged 738 00:28:03,557 --> 00:28:04,765 by the same swordsmiths 739 00:28:04,850 --> 00:28:06,684 that make the iconic japanese katana. 740 00:28:06,769 --> 00:28:09,186 They feature a thick spine and razor sharp edge 741 00:28:09,230 --> 00:28:11,855 that cuts effortlessly through any large fish. 742 00:28:11,899 --> 00:28:15,234 The maguro bocho is still used today by some japanese chefs, 743 00:28:15,319 --> 00:28:17,069 and can be seen on full display 744 00:28:17,154 --> 00:28:19,697 at some of tokyo's iconic fish markets. 745 00:28:19,740 --> 00:28:20,864 ♪ ♪ 746 00:28:20,950 --> 00:28:22,366 - now, when you guys build your blades, 747 00:28:22,451 --> 00:28:23,992 I want you to follow these parameters. 748 00:28:24,078 --> 00:28:26,537 Your blade length needs to be between 29 and 31 inches. 749 00:28:26,580 --> 00:28:28,956 You need to have a single edge, chisel grind. 750 00:28:29,041 --> 00:28:30,833 And I also want you to incorporate a ricasso 751 00:28:30,918 --> 00:28:32,584 between the handle and the blade. 752 00:28:32,670 --> 00:28:34,503 - I'm feeling pretty nervous. 753 00:28:34,547 --> 00:28:37,381 I'm gonna have to forge the longest blade I've ever made. 754 00:28:37,425 --> 00:28:39,299 - Gentlemen, we'll see you guys in four days. 755 00:28:39,385 --> 00:28:40,384 Good luck. - All right. 756 00:28:40,428 --> 00:28:41,719 - Good luck, man. - Yeah. 757 00:28:41,762 --> 00:28:46,724 ♪ ♪ 758 00:28:46,809 --> 00:28:49,393 we're here at my home forge in chambersburg, pennsylvania. 759 00:28:49,437 --> 00:28:52,354 My game plan is, I'm going to san mai. 760 00:28:52,398 --> 00:28:54,732 Give her little flux. 761 00:28:54,775 --> 00:28:56,442 My biggest concern right now is 762 00:28:56,527 --> 00:28:59,903 just getting the weld set. 763 00:28:59,989 --> 00:29:01,363 So now what I'm about to do, 764 00:29:01,407 --> 00:29:02,906 I'm gonna put it in the vise, 765 00:29:02,950 --> 00:29:05,242 cut a little bit off, see if we forge welded. 766 00:29:05,286 --> 00:29:07,035 It's not looking good for my billet. 767 00:29:07,121 --> 00:29:09,371 It doesn't matter how far I grind, 768 00:29:09,457 --> 00:29:11,123 delams keep popping up. 769 00:29:11,208 --> 00:29:14,251 Day one did not go exactly as I planned. 770 00:29:14,295 --> 00:29:17,087 Just gonna scrap it and start fresh in the morning. 771 00:29:17,131 --> 00:29:20,758 It kind of sucks that I wasted the whole day. 772 00:29:20,801 --> 00:29:23,427 ♪ ♪ 773 00:29:23,471 --> 00:29:25,220 - I'm back in mount laurel, new jersey, 774 00:29:25,306 --> 00:29:26,930 at my home forge, and I am ready 775 00:29:26,974 --> 00:29:29,141 to get started on my maguro bocho build. 776 00:29:29,226 --> 00:29:30,976 So this tuna sword is probably 777 00:29:31,061 --> 00:29:33,729 about twice as long as anything I've ever made. 778 00:29:33,773 --> 00:29:35,105 I got to get the forge hot, 779 00:29:35,191 --> 00:29:37,441 and I'm ready to put my 80crv2 in there 780 00:29:37,526 --> 00:29:40,569 and get hammering. 781 00:29:40,613 --> 00:29:41,945 It's pretty malleable steel, 782 00:29:41,989 --> 00:29:45,073 so, so far, things are going pretty quickly. 783 00:29:45,159 --> 00:29:48,744 This sword is way longer than anything I've ever made before, 784 00:29:48,788 --> 00:29:51,747 but I just kept hammering away 785 00:29:51,832 --> 00:29:54,625 and everything came out pretty well. 786 00:29:54,668 --> 00:29:56,627 Feeling pretty good about this. 787 00:29:56,670 --> 00:29:58,420 ♪ ♪ 788 00:29:58,506 --> 00:30:01,465 - it's day two. Yesterday was a wash, 789 00:30:01,509 --> 00:30:04,968 but I learned from it, so I know what not to do. 790 00:30:05,012 --> 00:30:06,428 We're getting there. 791 00:30:06,514 --> 00:30:07,721 Today the heat treat is 792 00:30:07,807 --> 00:30:09,765 the biggest thing I'm concerned with. 793 00:30:09,850 --> 00:30:11,767 My goal is to get a hardened blade. 794 00:30:11,852 --> 00:30:14,978 ♪ ♪ 795 00:30:15,022 --> 00:30:18,774 oh, I got a nice little warp in that...Bad boy. 796 00:30:18,859 --> 00:30:20,818 I start the day with nothing. 797 00:30:20,903 --> 00:30:24,029 No knife, no billet. I have to start all fresh. 798 00:30:24,114 --> 00:30:25,447 And now this. 799 00:30:25,533 --> 00:30:26,990 Oh, I'm so mad. 800 00:30:27,034 --> 00:30:28,116 ♪ ♪ 801 00:30:28,202 --> 00:30:29,993 - it's the beginning of day two. 802 00:30:30,037 --> 00:30:31,620 I'm really comfortable with where I'm at, 803 00:30:31,705 --> 00:30:34,164 but I want to keep making progress as fast as possible. 804 00:30:34,208 --> 00:30:35,582 Once the quench comes, that's kind of 805 00:30:35,668 --> 00:30:37,501 the make or break situation for me today. 806 00:30:37,545 --> 00:30:39,962 So I'm just trying to get the heat right. 807 00:30:40,047 --> 00:30:42,965 ♪ ♪ 808 00:30:43,050 --> 00:30:44,508 yeah, we're in good shape. 809 00:30:44,552 --> 00:30:47,010 It looks good, but just to be safe, 810 00:30:47,054 --> 00:30:49,555 I grab a file to do a file test. 811 00:30:49,640 --> 00:30:51,139 Hmm. 812 00:30:51,225 --> 00:30:54,476 As I go over the center of the blade, I hit a soft spot, 813 00:30:54,520 --> 00:30:56,144 and now I'm panicking. 814 00:30:56,230 --> 00:30:57,312 Of course, that's probably 815 00:30:57,398 --> 00:30:58,981 where they'll be hitting the blade, 816 00:30:59,066 --> 00:31:01,233 so that's the most important section of it. 817 00:31:01,318 --> 00:31:02,651 [bleep]. 818 00:31:05,281 --> 00:31:06,989 Ld pick up at a warp. 819 00:31:07,074 --> 00:31:08,949 It could crack. 820 00:31:09,034 --> 00:31:11,743 I'm going to compare that somewhat soft spot 821 00:31:11,829 --> 00:31:13,495 in the middle of the blade to the tang. 822 00:31:13,581 --> 00:31:15,330 And once I compare those with the file, 823 00:31:15,416 --> 00:31:17,249 I know that that blade is hard. 824 00:31:17,334 --> 00:31:20,210 I think there was some soft steel or scale on the outside. 825 00:31:20,296 --> 00:31:23,046 I'm feeling a little bit more confident in my heat treat, 826 00:31:23,132 --> 00:31:24,423 and now I'm ready to move forward. 827 00:31:24,508 --> 00:31:27,885 Little scare there, but I think I'm in good shape. 828 00:31:27,928 --> 00:31:29,136 ♪ ♪ 829 00:31:29,221 --> 00:31:31,263 - almost there. It's day four. 830 00:31:31,348 --> 00:31:35,017 This whole competition did not go exactly as I planned, 831 00:31:35,060 --> 00:31:36,852 but I've been able to catch up. 832 00:31:36,937 --> 00:31:38,645 I'm in a good spot right now, 833 00:31:38,731 --> 00:31:40,230 and all I have to do is get her assembled, 834 00:31:40,316 --> 00:31:42,691 get her polished, and sent out the door. 835 00:31:42,776 --> 00:31:44,067 Get all the pins cut down. 836 00:31:44,111 --> 00:31:46,278 It's time to hog some material off. 837 00:31:46,363 --> 00:31:49,072 Got about four hours left in this competition, 838 00:31:49,158 --> 00:31:51,617 and I still have a fair amount of work to do. 839 00:31:51,702 --> 00:31:53,702 I know for a fact that I'm at parameters. 840 00:31:53,746 --> 00:31:55,954 It's the one thing that I've been checking 841 00:31:56,040 --> 00:31:58,916 over and over and over again. 842 00:31:59,001 --> 00:32:01,585 It's the end of day four. I never gave up. 843 00:32:01,629 --> 00:32:02,920 ♪ ♪ 844 00:32:03,005 --> 00:32:05,047 finding out that the tumor has come back 845 00:32:05,132 --> 00:32:07,633 made it clear that you have to go all out. 846 00:32:07,718 --> 00:32:10,677 If it's not working out, adapt, overcome, 847 00:32:10,763 --> 00:32:12,262 and just put it all on the chopping block. 848 00:32:12,306 --> 00:32:13,430 You have nothing to lose. 849 00:32:15,392 --> 00:32:17,684 - So it's day four. This is the home stretch. 850 00:32:17,770 --> 00:32:19,186 It's time to get everything fit, assembled, 851 00:32:19,271 --> 00:32:22,272 and finish this blade. 852 00:32:22,316 --> 00:32:26,068 ♪ ♪ 853 00:32:26,153 --> 00:32:28,570 all right, we got a nice clean fit. 854 00:32:28,656 --> 00:32:31,448 That is the first look at what will soon be a finished blade. 855 00:32:31,533 --> 00:32:33,951 Overall, I think that I've managed my time well 856 00:32:34,036 --> 00:32:36,620 and I'm a really good spot to get this blade finished up. 857 00:32:36,705 --> 00:32:38,121 All right. 858 00:32:38,165 --> 00:32:39,831 Now that I have the final assembly finished, 859 00:32:39,917 --> 00:32:42,084 I didn't come up with an elaborate test, 860 00:32:42,169 --> 00:32:44,086 but I used to work in a sushi restaurant, 861 00:32:44,171 --> 00:32:45,587 and this is a tuna sword. 862 00:32:45,673 --> 00:32:47,130 ♪ ♪ 863 00:32:47,216 --> 00:32:48,799 it cut pretty clean. 864 00:32:48,842 --> 00:32:50,425 ♪ ♪ 865 00:32:50,469 --> 00:32:52,135 I think it does the job. 866 00:32:52,179 --> 00:32:57,057 ♪ ♪ 867 00:32:57,142 --> 00:32:59,351 - all right, gentlemen, welcome back to the forge. 868 00:32:59,436 --> 00:33:02,813 You have had four days to work on your maguro bochos. 869 00:33:02,856 --> 00:33:04,064 Justin, how'd it go for you? 870 00:33:04,149 --> 00:33:06,775 - It's been a struggle, but we got her completed. 871 00:33:06,860 --> 00:33:08,735 ♪ ♪ 872 00:33:08,821 --> 00:33:10,821 she's 1095, differentially heat-treated 873 00:33:10,906 --> 00:33:14,533 with a bocote handle and a ziricote bolster. 874 00:33:14,618 --> 00:33:15,993 - Well, awesome. Doug? 875 00:33:16,078 --> 00:33:17,160 - It went pretty well. 876 00:33:17,204 --> 00:33:18,453 ♪ ♪ 877 00:33:18,539 --> 00:33:20,247 it's an 80crv2 blade. 878 00:33:20,332 --> 00:33:24,334 I have a maple handle and a carbon fiber bolster. 879 00:33:24,420 --> 00:33:26,628 - They both look deadly, but the only way for us to know 880 00:33:26,714 --> 00:33:28,130 if they work as well as they look 881 00:33:28,173 --> 00:33:29,965 is to put them through a few tests. 882 00:33:30,009 --> 00:33:32,926 And up first, the keal test. Doug? 883 00:33:33,012 --> 00:33:35,554 ♪ ♪ 884 00:33:35,639 --> 00:33:37,014 - all right, bladesmiths, 885 00:33:37,099 --> 00:33:39,099 to find out what kind of lethal damage 886 00:33:39,184 --> 00:33:41,518 your maguro bochos will do, I'll take your weapon 887 00:33:41,562 --> 00:33:45,022 and make some lethal cuts on these six different fishes. 888 00:33:45,065 --> 00:33:46,606 ♪ ♪ 889 00:33:46,692 --> 00:33:48,358 justin, you're up first. You ready for this? 890 00:33:48,402 --> 00:33:50,652 - Let's make some sushi. - Let's do it. 891 00:33:50,738 --> 00:33:51,695 ♪ ♪ 892 00:33:51,780 --> 00:33:53,196 - I didn't test my blade. 893 00:33:53,240 --> 00:33:55,198 I was gonna let the judges deal with that, 894 00:33:55,284 --> 00:33:57,576 so I don't know if this is gonna perform 895 00:33:57,661 --> 00:33:59,036 how I want it to. 896 00:33:59,121 --> 00:34:01,705 If I didn't get my chisel grind just right, 897 00:34:01,790 --> 00:34:04,166 this could possibly cost me the round. 898 00:34:04,251 --> 00:34:11,339 ♪ ♪ 899 00:34:21,727 --> 00:34:24,269 - way to go, man. - Thanks. 900 00:34:24,354 --> 00:34:26,730 - All right, justin, let's talk about your weapon here. 901 00:34:26,774 --> 00:34:28,690 First up, your edge. 902 00:34:28,734 --> 00:34:30,984 One and done for all the cuts here. 903 00:34:31,070 --> 00:34:33,195 It's a very sharp edge. 904 00:34:33,280 --> 00:34:35,113 I like the handle construction here. 905 00:34:35,199 --> 00:34:38,617 It's ovoid, so my hand matches nicely and wraps around it. 906 00:34:38,702 --> 00:34:41,745 Overall, sir, it will keal. 907 00:34:41,830 --> 00:34:43,497 - Thank you. 908 00:34:43,582 --> 00:34:45,624 - All right, doug, you're up next. You ready? 909 00:34:45,709 --> 00:34:47,501 - Have at it. - Let's do it. 910 00:34:47,586 --> 00:34:51,254 ♪ ♪ 911 00:34:51,340 --> 00:34:53,590 - I kind of bent the blade a little bit at home 912 00:34:53,634 --> 00:34:54,883 to make sure it was strong, 913 00:34:54,968 --> 00:34:56,551 but you never know if that edge could roll 914 00:34:56,637 --> 00:34:57,886 if I didn't get the heat treat right. 915 00:34:57,971 --> 00:34:59,971 I'm just hoping it stays together. 916 00:35:00,057 --> 00:35:01,348 It's a little nerve-racking. 917 00:35:01,433 --> 00:35:08,438 ♪ ♪ 918 00:35:19,159 --> 00:35:21,034 - nice job, man. - All right. 919 00:35:21,120 --> 00:35:22,119 - All right, doug, 920 00:35:22,204 --> 00:35:24,204 first up, the handle construction. 921 00:35:24,289 --> 00:35:26,665 I really like the way you shaped your handle here. 922 00:35:26,750 --> 00:35:28,083 It's typical japanese-style. 923 00:35:28,168 --> 00:35:30,585 Now, it's a lighter blade, 924 00:35:30,671 --> 00:35:33,213 but your edge is so sharp 925 00:35:33,298 --> 00:35:36,466 it cut cleanly through the fishes, easily. 926 00:35:36,510 --> 00:35:39,219 Overall, sir, it will keal. 927 00:35:39,304 --> 00:35:40,971 - Thanks. 928 00:35:41,014 --> 00:35:42,472 ♪ ♪ 929 00:35:42,558 --> 00:35:44,641 - all right, gentlemen, I think you know what time it is. 930 00:35:44,726 --> 00:35:45,934 It's time for the strength test. 931 00:35:46,019 --> 00:35:48,854 Now, we're calling this our bo staff attack. 932 00:35:48,939 --> 00:35:50,814 Now, justin, 933 00:35:50,858 --> 00:35:52,774 your weapon is already locked in our device here, 934 00:35:52,818 --> 00:35:55,694 and I will be attacking it with our wax wood bo staffs. 935 00:35:55,779 --> 00:35:58,822 This test is not about what your blades do to that staff, 936 00:35:58,907 --> 00:36:00,657 but what that staff's gonna do to your blade. 937 00:36:00,742 --> 00:36:02,117 - All right. - Y'all ready? 938 00:36:02,202 --> 00:36:03,994 - Let's do it. - Okay. 939 00:36:04,037 --> 00:36:09,166 ♪ ♪ 940 00:36:09,209 --> 00:36:11,668 [grunting] 941 00:36:11,712 --> 00:36:18,800 ♪ ♪ 942 00:36:26,351 --> 00:36:27,642 all right, justin, 943 00:36:27,728 --> 00:36:29,686 you know, this is a brutal test 944 00:36:29,771 --> 00:36:32,022 for what is technically a large kitchen knife, 945 00:36:32,065 --> 00:36:34,149 but you did very, very well. 946 00:36:34,234 --> 00:36:36,526 Right where my finger is, 947 00:36:36,612 --> 00:36:38,737 there's the smallest of chips. 948 00:36:38,822 --> 00:36:40,488 And when I say smallest of chips, 949 00:36:40,574 --> 00:36:42,699 I mean it's really small. 950 00:36:42,743 --> 00:36:44,868 Everything else looks right and tight. 951 00:36:44,912 --> 00:36:46,203 All in all, you did a great job. 952 00:36:46,288 --> 00:36:47,329 You survived. 953 00:36:47,414 --> 00:36:49,539 - Thank you. - You bet. 954 00:36:49,625 --> 00:36:51,416 All right, doug, you're up. You ready? 955 00:36:51,501 --> 00:36:53,210 - As ready as I can be. - Okay. 956 00:36:53,295 --> 00:36:55,295 'cause this is fun for me. [both laugh] 957 00:36:55,380 --> 00:36:56,796 ♪ ♪ 958 00:36:56,882 --> 00:36:59,841 - this blade is made for delicate cutting of sushi. 959 00:36:59,927 --> 00:37:02,636 It is not designed to take any abuse. 960 00:37:02,721 --> 00:37:03,929 ♪ ♪ 961 00:37:04,014 --> 00:37:05,430 I'm--I'm getting really worried. 962 00:37:05,515 --> 00:37:07,557 When I saw justin's blade have 963 00:37:07,643 --> 00:37:09,893 one little, unnoticeable nick, 964 00:37:09,978 --> 00:37:11,269 I'm kind of already thinking 965 00:37:11,355 --> 00:37:13,230 that justin's got this test won. 966 00:37:13,273 --> 00:37:17,776 ♪ ♪ 967 00:37:17,861 --> 00:37:20,153 -[grunting] 968 00:37:20,239 --> 00:37:27,077 ♪ ♪ 969 00:37:31,500 --> 00:37:33,416 so doug, right off, 970 00:37:33,460 --> 00:37:35,710 this is a remarkably light. 971 00:37:35,796 --> 00:37:38,713 There is the slightest rough spot, 972 00:37:38,799 --> 00:37:42,342 but besides that, I don't see any deformation in your blade. 973 00:37:42,427 --> 00:37:45,929 The blade's as straight as it was when we started out. 974 00:37:46,014 --> 00:37:47,931 It's a good, solid piece. Well done. 975 00:37:47,975 --> 00:37:50,475 - Thank you. - So all right, gentlemen, 976 00:37:50,560 --> 00:37:52,352 two tests down, one test to go. 977 00:37:52,437 --> 00:37:54,980 ♪ ♪ 978 00:37:55,065 --> 00:37:58,775 - all right, bladesmiths, we're cutting it close. 979 00:37:58,860 --> 00:38:01,278 We know that both your weapons can keal, 980 00:38:01,321 --> 00:38:03,029 and we know they're strong. 981 00:38:03,115 --> 00:38:05,115 Now it's time to find out how sharp they are. 982 00:38:05,158 --> 00:38:07,617 This is the sharpness test. 983 00:38:07,703 --> 00:38:10,370 To find out how sharp your weapons are, 984 00:38:10,455 --> 00:38:12,289 I will cut through these rolled-up tatami mats. 985 00:38:12,374 --> 00:38:15,041 Now, unlike the strength test, this is all about 986 00:38:15,127 --> 00:38:17,711 what the edge of your weapon will do to these mats. 987 00:38:17,796 --> 00:38:19,879 Justin, you're up first. You ready for this? 988 00:38:19,965 --> 00:38:22,132 - Rock and roll. - All right, let's do that. 989 00:38:22,175 --> 00:38:26,678 ♪ ♪ 990 00:38:26,763 --> 00:38:29,723 [exhaling] 991 00:38:29,808 --> 00:38:36,813 ♪ ♪ 992 00:38:39,776 --> 00:38:41,943 all right, justin, let's talk about the cuts here. 993 00:38:41,987 --> 00:38:45,113 Clearly, on the other cuts, they cut all the way through. 994 00:38:45,157 --> 00:38:47,240 On the last cut, almost, 995 00:38:47,326 --> 00:38:50,118 but just a little skin of that mat is hanging on. 996 00:38:50,203 --> 00:38:51,661 But it is a sharp edge. 997 00:38:51,747 --> 00:38:54,247 Overall, sir, it will cut. 998 00:38:54,333 --> 00:38:55,749 - Thank you. - All right, doug, your turn. 999 00:38:55,834 --> 00:38:56,958 So you ready? 1000 00:38:57,044 --> 00:38:58,585 - Let's see what this thing can do. 1001 00:38:58,670 --> 00:39:00,420 - Let's do it. 1002 00:39:00,505 --> 00:39:07,010 ♪ ♪ 1003 00:39:07,095 --> 00:39:09,679 [exhaling] 1004 00:39:09,723 --> 00:39:16,686 ♪ ♪ 1005 00:39:22,402 --> 00:39:23,902 all right, doug, 1006 00:39:23,987 --> 00:39:26,696 first cut just went so easy without a drag 1007 00:39:26,782 --> 00:39:28,865 that it went into the next target. 1008 00:39:28,950 --> 00:39:30,700 It is a very sharp weapon. 1009 00:39:30,744 --> 00:39:33,828 It's very easy to wield, and it's light. 1010 00:39:33,914 --> 00:39:36,748 Overall, sir, it will cut. 1011 00:39:36,833 --> 00:39:39,125 - Thank you. 1012 00:39:39,211 --> 00:39:41,378 - All right, gentlemen, I know I speak for the judges 1013 00:39:41,421 --> 00:39:43,213 when I say this is exactly what we want to see-- 1014 00:39:43,298 --> 00:39:45,965 blades that not only perform well on our tests, 1015 00:39:46,051 --> 00:39:47,842 but are so close that we need to deliberate. 1016 00:39:47,928 --> 00:39:49,177 As you guys know, only one of you 1017 00:39:49,221 --> 00:39:50,553 will be leaving here with the win, 1018 00:39:50,597 --> 00:39:52,597 so while the judges deliberate, I'm gonna ask you 1019 00:39:52,682 --> 00:39:55,433 to please step off the forge floor. 1020 00:39:55,519 --> 00:39:56,643 All right, guys. 1021 00:39:56,728 --> 00:39:58,895 They both seem like they did pretty well. 1022 00:39:58,939 --> 00:40:00,688 - Both justin and doug wound up 1023 00:40:00,732 --> 00:40:02,899 with a small glinting spot on their blade, 1024 00:40:02,943 --> 00:40:05,318 but that was about it as far as the strength test goes. 1025 00:40:05,404 --> 00:40:07,195 But as far as I could see, 1026 00:40:07,280 --> 00:40:09,739 one blade was more fast, sharp, light, 1027 00:40:09,783 --> 00:40:11,741 and elegant, so-- - okay. 1028 00:40:11,785 --> 00:40:14,285 - It caught me off guard during the sharpness test 1029 00:40:14,371 --> 00:40:18,164 because it's light, but it's also a sharp blade. 1030 00:40:18,250 --> 00:40:19,958 - All right, so you guys made your decision? 1031 00:40:20,043 --> 00:40:21,000 - Oh, yeah. - All right. 1032 00:40:21,086 --> 00:40:22,001 I'll call them back in. 1033 00:40:22,087 --> 00:40:27,215 ♪ ♪ 1034 00:40:27,300 --> 00:40:28,383 first of all, both of you, 1035 00:40:28,468 --> 00:40:29,968 thank you very much for your hard work. 1036 00:40:30,053 --> 00:40:32,262 But as we know, only one of you is gonna be leaving here 1037 00:40:32,347 --> 00:40:35,765 the "forged in fire" champion with a check for $10,000. 1038 00:40:35,809 --> 00:40:38,351 And today's "forged in fire" champion is... 1039 00:40:38,437 --> 00:40:40,395 ♪ ♪ 1040 00:40:40,480 --> 00:40:42,272 doug. Congratulations, you won. 1041 00:40:42,357 --> 00:40:43,898 Justin, unfortunately you're not gonna be 1042 00:40:43,942 --> 00:40:46,484 leaving with the win today, and doug's gonna tell you why. 1043 00:40:46,570 --> 00:40:48,862 - Justin, on any other given competition, 1044 00:40:48,947 --> 00:40:50,738 I can see your blade being a champion's blade. 1045 00:40:50,782 --> 00:40:52,782 It is a beautiful blade. 1046 00:40:52,826 --> 00:40:55,160 But today your opponent's was just a little bit sharper, 1047 00:40:55,245 --> 00:40:56,786 a little lighter, and faster to wield. 1048 00:40:56,830 --> 00:40:59,038 - Justin, again, thank you very much for your hard work, 1049 00:40:59,124 --> 00:41:00,415 but unfortunately, I'm gonna have to ask you 1050 00:41:00,500 --> 00:41:01,416 to please leave the forge. 1051 00:41:01,460 --> 00:41:04,043 - Hey, good job. - Thank you. 1052 00:41:04,129 --> 00:41:07,464 - I'm glad that this time frame worked out as it did. 1053 00:41:07,507 --> 00:41:09,591 Chemo takes a toll on your body, 1054 00:41:09,634 --> 00:41:13,219 but going through that, and then do this whole competition 1055 00:41:13,305 --> 00:41:15,805 just goes to show myself 1056 00:41:15,891 --> 00:41:18,558 how much I can actually push through. 1057 00:41:18,643 --> 00:41:20,310 You know, I've always kind of been stubborn, 1058 00:41:20,353 --> 00:41:23,313 but I didn't realize how stubborn I am actually. 1059 00:41:23,356 --> 00:41:25,273 [laughs] 1060 00:41:25,358 --> 00:41:28,651 - well, doug, you are the "forged in fire" champion. 1061 00:41:28,695 --> 00:41:30,945 Congratulations, man. - Thanks a lot. 1062 00:41:31,031 --> 00:41:33,239 - What are you gonna get with that $10,000? 1063 00:41:33,325 --> 00:41:35,658 - Oh, I fell in love with the forge press, 1064 00:41:35,702 --> 00:41:38,953 so I definitely want one of those of my own. 1065 00:41:39,039 --> 00:41:40,497 I am ecstatic. 1066 00:41:40,582 --> 00:41:41,915 You know, I put a lot of heart and soul 1067 00:41:42,000 --> 00:41:43,333 into making that blade, 1068 00:41:43,376 --> 00:41:44,959 and seeing it perform the way that it did 1069 00:41:45,045 --> 00:41:47,128 was just a really great confirmation 1070 00:41:47,172 --> 00:41:48,671 about my abilities, 1071 00:41:48,715 --> 00:41:50,423 and it's just making me want to make more knives. 1072 00:41:50,509 --> 00:41:56,304 ♪ ♪