1 00:00:06,925 --> 00:00:10,595 [intense rock music] 2 00:00:10,679 --> 00:00:14,759 ♪ ♪ 3 00:00:14,849 --> 00:00:16,849 - My name is Dan Greene. 4 00:00:16,935 --> 00:00:18,855 I’m 25 years old. 5 00:00:18,937 --> 00:00:21,027 I’ve been making knives about three years now. 6 00:00:21,106 --> 00:00:24,986 From a very early age, I always liked tattoos. 7 00:00:25,110 --> 00:00:26,400 Actually gave myself this sleeve. 8 00:00:26,486 --> 00:00:28,826 In some ways, I would say it’s a little better 9 00:00:28,947 --> 00:00:31,457 than another artist to give you tattoos. 10 00:00:31,533 --> 00:00:33,823 Just...knuckles hurt quite a bit. 11 00:00:33,952 --> 00:00:36,332 - My name is Sean Meadows. 12 00:00:36,454 --> 00:00:37,704 I am 20 years old, 13 00:00:37,789 --> 00:00:40,329 and I am a full-time bladesmith and woodworker. 14 00:00:40,458 --> 00:00:43,788 My mother has lent me 1/2 of her garage 15 00:00:43,920 --> 00:00:45,790 to set my entire workshop up in. 16 00:00:45,880 --> 00:00:47,380 As much as I love being able to work 17 00:00:47,465 --> 00:00:48,885 in my mom’s garage, 18 00:00:48,967 --> 00:00:50,977 winning $10,000 would finally 19 00:00:51,052 --> 00:00:54,052 be the ticket that I need to move out into my own shop. 20 00:00:55,223 --> 00:00:56,853 - My name is JD Bostick. 21 00:00:56,975 --> 00:00:58,065 First learned to bladesmith 22 00:00:58,143 --> 00:00:59,313 about 12 years ago. 23 00:00:59,436 --> 00:01:01,276 I have two kids. 24 00:01:01,354 --> 00:01:04,404 Their names are Kaya and Miko. 25 00:01:04,482 --> 00:01:06,362 They inspired me to get on "Forged in Fire." 26 00:01:06,484 --> 00:01:09,234 They said, "Just don’t get out in the first round," 27 00:01:09,321 --> 00:01:10,821 so here’s hoping. 28 00:01:10,905 --> 00:01:14,495 - I’m Ron Berkland. I’m 50 years old. 29 00:01:14,618 --> 00:01:16,998 I’ve been bladesmithing for three years. 30 00:01:17,120 --> 00:01:18,490 I was in the military 31 00:01:18,580 --> 00:01:20,620 where I spent 18 years in the National Guard. 32 00:01:20,707 --> 00:01:22,257 And I spent four years active duty, 33 00:01:22,334 --> 00:01:24,004 so I did 22 years complete. 34 00:01:24,085 --> 00:01:25,635 My experiences in the military 35 00:01:25,712 --> 00:01:28,922 helped me feel like I can accomplish anything. 36 00:01:29,007 --> 00:01:31,597 - Bladesmiths, welcome to The Forge. 37 00:01:32,802 --> 00:01:34,592 The four of you have been chosen to take part 38 00:01:34,679 --> 00:01:36,849 in an intense bladesmithing competition 39 00:01:36,931 --> 00:01:39,061 that’ll all culminate with one of you leaving here 40 00:01:39,184 --> 00:01:40,604 with the title of "Forged in Fire" champion, 41 00:01:40,685 --> 00:01:42,735 and a check for $10,000. 42 00:01:42,854 --> 00:01:45,064 - What am I going to be expected to do? 43 00:01:45,190 --> 00:01:47,810 A canister, canoe Damascus. 44 00:01:47,901 --> 00:01:51,111 I am super excited but very nervous. 45 00:01:51,196 --> 00:01:52,786 - Bladesmiths, you’ve all got a cloth 46 00:01:52,864 --> 00:01:54,034 on the anvils in front of you. 47 00:01:54,115 --> 00:01:56,205 Go ahead and take that off for me. 48 00:01:56,326 --> 00:01:58,536 [exciting music] 49 00:01:58,662 --> 00:02:00,242 Bladesmiths, what you’re staring at there 50 00:02:00,372 --> 00:02:03,202 is a bar of W1 high-carbon steel. 51 00:02:03,333 --> 00:02:05,043 All we’re asking you to do 52 00:02:05,168 --> 00:02:06,708 is make a signature blade 53 00:02:06,836 --> 00:02:09,966 in your signature style using mono steel. 54 00:02:10,048 --> 00:02:11,468 - What’s the catch? 55 00:02:11,549 --> 00:02:14,049 It’s "Forged in Fire." There’s always a catch. 56 00:02:14,177 --> 00:02:15,807 - Now guys, just make sure 57 00:02:15,887 --> 00:02:18,227 that those blades fall within these following parameters. 58 00:02:18,306 --> 00:02:20,056 Your blade length measured from tip 59 00:02:20,141 --> 00:02:21,891 to where the cutting edge ends in a straight line 60 00:02:22,018 --> 00:02:24,768 needs to be between 11 and 13 inches. 61 00:02:24,896 --> 00:02:26,606 Each of you will have to turn in a blade 62 00:02:26,731 --> 00:02:28,561 that has a recurved edge. 63 00:02:28,650 --> 00:02:31,270 Now as far as designing for the test goes, 64 00:02:31,403 --> 00:02:32,823 I’m going to leave you in the dark there, guys. 65 00:02:32,904 --> 00:02:34,154 You’re not going to know 66 00:02:34,239 --> 00:02:35,399 how we’re going to test for strength 67 00:02:35,490 --> 00:02:36,990 or test for your edge retention 68 00:02:37,075 --> 00:02:38,495 until we get there. 69 00:02:38,576 --> 00:02:40,166 For this first round of competition, 70 00:02:40,245 --> 00:02:42,375 there are three hours on the clock. 71 00:02:42,455 --> 00:02:44,005 All right, gentlemen, good luck, 72 00:02:44,082 --> 00:02:46,412 stay sharp, your time starts... 73 00:02:46,501 --> 00:02:48,541 [lights power hum] 74 00:02:50,588 --> 00:02:53,708 - What the hell is going on? 75 00:02:53,800 --> 00:02:56,670 [dramatic music] 76 00:02:56,761 --> 00:02:59,551 - Bladesmiths, as you can see, we’re experiencing 77 00:02:59,639 --> 00:03:01,799 a bit of a blackout in The Forge today. 78 00:03:01,933 --> 00:03:03,933 Each of you has a lamp behind you. 79 00:03:04,060 --> 00:03:06,890 Go ahead and light then hang them up for me. 80 00:03:06,980 --> 00:03:08,940 Word is that the electrician will not be available 81 00:03:09,023 --> 00:03:12,273 to turn the power back on until after the second round. 82 00:03:12,360 --> 00:03:14,280 There’s no power to the power tools. 83 00:03:14,404 --> 00:03:17,704 The only things you have are the forges and hand tools. 84 00:03:17,782 --> 00:03:19,782 You didn’t think you’re gonna get off that easy, did you? 85 00:03:19,909 --> 00:03:21,199 - Nah. 86 00:03:21,286 --> 00:03:24,456 No power tools, no Big Blu, 87 00:03:24,581 --> 00:03:26,081 no drill press. 88 00:03:26,166 --> 00:03:27,716 It’s going to be challenging, 89 00:03:27,792 --> 00:03:29,332 but that’s the fun part of it. 90 00:03:29,461 --> 00:03:30,501 - At the end of each round, 91 00:03:30,628 --> 00:03:31,578 I will ask you to present your work 92 00:03:31,671 --> 00:03:33,171 to our panel of expert judges. 93 00:03:33,298 --> 00:03:35,218 They are the ones who’ll be deciding 94 00:03:35,300 --> 00:03:37,170 which three of you are leaving here empty-handed, 95 00:03:37,302 --> 00:03:38,342 and who’s going to be leaving here 96 00:03:38,470 --> 00:03:39,840 with the title of "Forged in Fire" champion, 97 00:03:39,971 --> 00:03:42,391 and that check for $10,000. 98 00:03:42,474 --> 00:03:45,774 Now, good luck, gentlemen, because your time starts now. 99 00:03:45,852 --> 00:03:49,312 [intense rock music] 100 00:03:49,397 --> 00:03:52,527 ♪ ♪ 101 00:03:52,650 --> 00:03:54,190 Now I got to really pay attention to my watch 102 00:03:54,319 --> 00:03:55,399 ’cause with the power going down, 103 00:03:55,487 --> 00:03:56,737 the clock’s out too. 104 00:03:56,821 --> 00:03:59,151 These guys have no clock to reference 105 00:03:59,282 --> 00:04:00,862 how long they’ve got left. 106 00:04:00,992 --> 00:04:04,582 We’ve never done a no electricity competition. 107 00:04:04,662 --> 00:04:06,372 - Yeah, I mean, the only time we’ve ever done 108 00:04:06,498 --> 00:04:08,338 something that was even close is when we were doing 109 00:04:08,458 --> 00:04:09,798 a coal forge situation. - Right. 110 00:04:09,876 --> 00:04:11,756 - And even then, they usually had 111 00:04:11,836 --> 00:04:14,216 electric angle grinders and things like that. 112 00:04:14,339 --> 00:04:17,759 - I am very concerned about overexertion 113 00:04:17,842 --> 00:04:19,262 going into this competition. 114 00:04:19,344 --> 00:04:21,434 I’m gonna need to make sure 115 00:04:21,513 --> 00:04:23,433 that I don’t get off to too hot of a start, 116 00:04:23,515 --> 00:04:25,685 or else I’m never going to be able to finish. 117 00:04:25,767 --> 00:04:29,567 - Learning how metal moves under a hammer on an anvil 118 00:04:29,687 --> 00:04:31,987 are things that a lot of smiths don’t learn. 119 00:04:32,065 --> 00:04:34,525 Most of the stock that we start out with 120 00:04:34,609 --> 00:04:36,769 is already in a bar form. 121 00:04:36,861 --> 00:04:38,741 - I learned all of my skills 122 00:04:38,863 --> 00:04:40,653 from watching videos online. 123 00:04:40,740 --> 00:04:42,610 Feeling like I’m at a disadvantage, 124 00:04:42,700 --> 00:04:45,070 but I’m still gonna try my best. 125 00:04:45,870 --> 00:04:48,490 ♪ ♪ 126 00:04:48,581 --> 00:04:50,541 - I’m excited about seeing this competition, 127 00:04:50,625 --> 00:04:52,585 but we would have had electricity, Dave, 128 00:04:52,710 --> 00:04:53,790 if you would remember to pay the damn bill. 129 00:04:53,878 --> 00:04:54,998 - [laughs] 130 00:04:55,088 --> 00:04:59,638 - I had used W1 for a few projects. 131 00:04:59,717 --> 00:05:02,477 I have not moved this much W1 132 00:05:02,554 --> 00:05:04,434 and moved it to this extreme, 133 00:05:04,556 --> 00:05:06,436 so this is gonna be a big challenge. 134 00:05:06,558 --> 00:05:11,238 I want to stretch out the bar to meet my blade requirement. 135 00:05:11,312 --> 00:05:13,142 So that’s my biggest focus. 136 00:05:16,067 --> 00:05:18,487 - Just gotta get a blade I can turn in. 137 00:05:18,570 --> 00:05:20,650 W1, it’s really hard to work 138 00:05:20,738 --> 00:05:22,698 and we get a 1-inch round of it, 139 00:05:22,782 --> 00:05:25,412 and we gotta draw this out... 140 00:05:25,493 --> 00:05:26,413 Without power. 141 00:05:26,494 --> 00:05:28,124 If steel gets too cold, 142 00:05:28,246 --> 00:05:30,166 you can definitely develop cracks in W1. 143 00:05:30,248 --> 00:05:33,928 So, I gotta keep it hot and keep it moving. 144 00:05:34,002 --> 00:05:35,422 [bleep]. 145 00:05:35,503 --> 00:05:38,003 I’m hammering hot metal, have a piece of slag hop off 146 00:05:38,089 --> 00:05:40,879 and land right on my index finger. 147 00:05:40,967 --> 00:05:43,017 And I can immediately feel it blistering. 148 00:05:43,094 --> 00:05:44,934 Thank you. 149 00:05:45,013 --> 00:05:47,433 - If any guy gets an injury that keeps them 150 00:05:47,557 --> 00:05:48,977 from being able to swing, that can take him 151 00:05:49,100 --> 00:05:50,520 out of the competition completely. 152 00:05:50,602 --> 00:05:52,852 They couldn’t go rely on Big Blu or the presses. 153 00:05:52,937 --> 00:05:54,697 - I just got to push through the pain. 154 00:05:54,772 --> 00:05:56,732 I can’t waste any more time. 155 00:05:57,775 --> 00:06:00,575 ♪ ♪ 156 00:06:00,653 --> 00:06:03,533 - Doing what these guys are doing with hand tools 157 00:06:03,615 --> 00:06:07,035 in three hours is very, very abnormal. 158 00:06:07,118 --> 00:06:08,238 - Very interesting. 159 00:06:08,328 --> 00:06:10,458 Dan is kind of ambidextrous right there. 160 00:06:10,538 --> 00:06:12,198 He was just hammering in one hand 161 00:06:12,290 --> 00:06:13,700 and switched over and used the other hand. 162 00:06:13,791 --> 00:06:16,121 - I’ve taught myself how to use both hands, 163 00:06:16,252 --> 00:06:17,792 left and right, forging. 164 00:06:17,879 --> 00:06:19,539 I’m going to use it as much as I can 165 00:06:19,631 --> 00:06:21,551 in order not to tire my right arm out. 166 00:06:21,633 --> 00:06:23,633 Even though I’m using both hands, 167 00:06:23,760 --> 00:06:26,430 man, it would be fantastic to have a press right now, 168 00:06:26,512 --> 00:06:29,552 ’cause this is brutal. 169 00:06:29,641 --> 00:06:32,471 - All right, bladesmiths, you are 30 minutes in. 170 00:06:32,560 --> 00:06:34,600 You have 2 hours and 30 minutes left. 171 00:06:34,687 --> 00:06:36,197 - Whoo-wee! 172 00:06:36,314 --> 00:06:37,654 - [chuckles] You’re very welcome. 173 00:06:37,732 --> 00:06:40,822 - You can start to see Sean’s profile coming in now. 174 00:06:40,944 --> 00:06:42,904 Just how is he going to work in that recurve? 175 00:06:42,987 --> 00:06:44,907 - The biggest issue is that I’m not used to 176 00:06:44,989 --> 00:06:46,529 working with stock that’s this thick. 177 00:06:46,658 --> 00:06:48,288 - We know what kind of blades they’re making, 178 00:06:48,368 --> 00:06:49,538 I asked for a recurve. 179 00:06:49,661 --> 00:06:51,331 But is there anything really 180 00:06:51,454 --> 00:06:53,374 they can be doing to get ahead of the game? 181 00:06:53,498 --> 00:06:55,338 - With not having the power tools, 182 00:06:55,416 --> 00:06:57,506 they really need to use every portion of that anvil. 183 00:06:57,585 --> 00:07:00,005 - Exactly. - Especially the horn 184 00:07:00,129 --> 00:07:01,419 for that recurve. 185 00:07:01,506 --> 00:07:03,346 That’s what the horn of the anvil is meant for. 186 00:07:03,424 --> 00:07:05,174 - I got this thing looking good. 187 00:07:05,259 --> 00:07:07,339 Now I can move forward. 188 00:07:07,470 --> 00:07:09,090 I think I got it. 189 00:07:09,180 --> 00:07:11,680 - ♪ And that’s the way you do it ♪ 190 00:07:11,808 --> 00:07:13,438 I have my blade length, 191 00:07:13,518 --> 00:07:16,028 so now I can work on the shape of my blade. 192 00:07:16,104 --> 00:07:18,234 I don’t know the tests, 193 00:07:18,356 --> 00:07:21,196 but a recurve tells me there’s possibly a chop test. 194 00:07:21,317 --> 00:07:24,037 And then I have to figure in that it could be a stab test, 195 00:07:24,112 --> 00:07:25,902 so I have to have a decent tip on my blade. 196 00:07:26,030 --> 00:07:28,530 - This is one of those competitions that having 197 00:07:28,616 --> 00:07:30,996 a knowledge of a lot of different knife shapes 198 00:07:31,077 --> 00:07:32,457 would really pay off. 199 00:07:32,537 --> 00:07:33,957 Because you can start thinking, okay, 200 00:07:34,038 --> 00:07:36,448 what shape is going to allow me to move 201 00:07:36,541 --> 00:07:39,171 the least amount of metal in the quickest amount of time? 202 00:07:39,252 --> 00:07:40,712 - It’s getting there. 203 00:07:40,795 --> 00:07:43,295 My wife is a big Doug fan. 204 00:07:43,381 --> 00:07:47,881 So I want to try to impress Doug with my blade. 205 00:07:49,971 --> 00:07:53,181 - We have to have a recurve in the blade. 206 00:07:53,266 --> 00:07:54,476 Doing good. 207 00:07:54,559 --> 00:07:56,019 If I don’t give it enough belly, 208 00:07:56,102 --> 00:07:57,892 it’s not going to look like a recurve. 209 00:07:58,021 --> 00:07:59,771 I really want to hear Doug say that my knife’s 210 00:07:59,897 --> 00:08:00,987 "sexy." 211 00:08:02,233 --> 00:08:04,613 - JD is having some trouble moving that steel. 212 00:08:04,736 --> 00:08:07,576 - Seeing some of those really deep curves in the blade 213 00:08:07,697 --> 00:08:09,327 get hung up in testing material. 214 00:08:09,407 --> 00:08:12,167 - Having the blister forming is tough. 215 00:08:12,243 --> 00:08:15,493 I’m feeling the grip already getting sore. 216 00:08:15,580 --> 00:08:17,870 [grunts] That bitch is heavy. 217 00:08:17,957 --> 00:08:21,257 But you just have to keep going. 218 00:08:21,335 --> 00:08:26,255 ♪ ♪ 219 00:08:26,382 --> 00:08:30,262 - I got my blade to length. So now I can start shaping it. 220 00:08:30,386 --> 00:08:32,436 I’ll probably call the blade shape that I’m going for 221 00:08:32,555 --> 00:08:34,355 some kind of a kukri. 222 00:08:34,432 --> 00:08:35,562 Looks good. 223 00:08:35,641 --> 00:08:37,601 - Dan’s blade is one of the nicer shapes 224 00:08:37,685 --> 00:08:38,855 I’ve seen in a long time. 225 00:08:38,936 --> 00:08:40,856 And he’s doing it all by hand. 226 00:08:40,938 --> 00:08:43,098 - I feel pretty good about the shape. 227 00:08:43,232 --> 00:08:46,192 But I just know I need to get a move on the tang 228 00:08:46,277 --> 00:08:49,787 ’cause that’s gonna be fairly time-consuming to draw out. 229 00:08:49,864 --> 00:08:52,864 ♪ ♪ 230 00:08:52,950 --> 00:08:54,620 - I’m gonna try to get just a bit more length 231 00:08:54,744 --> 00:08:56,164 and then get to driftin’. 232 00:08:56,287 --> 00:08:57,627 - I’ve never drifted a hole. 233 00:08:57,705 --> 00:08:58,625 Always drilling. - Never? 234 00:08:58,706 --> 00:09:00,546 - Never. - I’ve done it like twice. 235 00:09:00,625 --> 00:09:01,875 It’s awful. 236 00:09:01,959 --> 00:09:03,369 Normally, you’re just gonna drill 237 00:09:03,461 --> 00:09:05,381 right through the material, and it’s super easy. 238 00:09:05,463 --> 00:09:08,503 But I don’t have power for a drill press, 239 00:09:08,633 --> 00:09:10,883 so I have to finish up these punches before quench, 240 00:09:10,968 --> 00:09:12,468 because as soon as the quench happens, 241 00:09:12,553 --> 00:09:15,433 the blade will be too hard to punch pin holes. 242 00:09:15,515 --> 00:09:17,765 But, luckily, drifting these tang holes 243 00:09:17,850 --> 00:09:19,560 is surprisingly easy. 244 00:09:19,644 --> 00:09:20,734 Hell yeah! 245 00:09:20,812 --> 00:09:22,352 So I am riding high. 246 00:09:22,480 --> 00:09:24,770 ♪ ♪ 247 00:09:24,857 --> 00:09:26,317 - Come on, baby! 248 00:09:26,442 --> 00:09:29,152 I’m putting in the bevels on my blade. 249 00:09:29,278 --> 00:09:31,148 Trying to put in the edge on this 250 00:09:31,280 --> 00:09:32,530 is gonna be very difficult 251 00:09:32,657 --> 00:09:35,247 without power tools after it’s tempered. 252 00:09:35,326 --> 00:09:37,836 - Developing the traditional skill sets 253 00:09:37,954 --> 00:09:40,334 with just hammer and anvil really allows you 254 00:09:40,414 --> 00:09:41,914 to branch out and do other things. 255 00:09:41,999 --> 00:09:44,499 - I’m pretty confident I’m going 256 00:09:44,585 --> 00:09:46,835 to accomplish this in the time I have left. 257 00:09:49,215 --> 00:09:52,385 - Ten, nine, eight... 258 00:09:52,510 --> 00:09:53,510 Naw, I’m just kidding, guys. 259 00:09:53,636 --> 00:09:54,806 You’re halfway through. 260 00:09:54,887 --> 00:09:56,517 You have 90 minutes left. 261 00:09:56,597 --> 00:09:58,517 - That’s not funny. - [chuckles] 262 00:09:58,641 --> 00:10:00,391 - If you’re up there it’s funny. 263 00:10:00,518 --> 00:10:02,608 It’s not funny out here. - [chuckles] 264 00:10:02,687 --> 00:10:04,607 After I’ve got these holes drifted through, 265 00:10:04,689 --> 00:10:06,979 next thing I know Dan and Sean, 266 00:10:07,066 --> 00:10:09,776 they are already putting a bevel on this thing. 267 00:10:09,861 --> 00:10:12,191 [bleep], you guys are way ahead of me. 268 00:10:13,573 --> 00:10:16,033 I realized I was falling behind at this point. 269 00:10:16,159 --> 00:10:20,119 So I’ve got to get a bevel in this blade and fast. 270 00:10:20,204 --> 00:10:22,204 But I’ve never filed a bevel into a blade before. 271 00:10:22,331 --> 00:10:23,791 So I’m making the choice 272 00:10:23,875 --> 00:10:25,165 to go with my flattening hammer. 273 00:10:25,251 --> 00:10:27,211 - This right now is gonna be hard for these guys. 274 00:10:27,295 --> 00:10:29,715 They gotta forge those bevels all the way in. 275 00:10:29,797 --> 00:10:32,097 You can’t get a part of the way and grind it down, 276 00:10:32,216 --> 00:10:34,306 so you got to get that drawn all the way down. 277 00:10:34,385 --> 00:10:36,185 - The flattening hammer works great 278 00:10:36,262 --> 00:10:37,842 to beat a bevel into this thing. 279 00:10:37,930 --> 00:10:39,390 I feel like I made up a lot of ground 280 00:10:39,515 --> 00:10:41,145 in the last 30 minutes 281 00:10:41,225 --> 00:10:43,565 and the end is within sight. 282 00:10:45,313 --> 00:10:46,483 - Feeling it, man. 283 00:10:46,564 --> 00:10:48,564 I feel pretty good about my bevels. 284 00:10:48,691 --> 00:10:51,191 But now I’d have to punch holes. 285 00:10:51,277 --> 00:10:52,487 I’m a little nervous. 286 00:10:52,570 --> 00:10:54,240 I’ve actually never done that before, 287 00:10:54,363 --> 00:10:55,743 but we’ll see how it goes. 288 00:10:55,865 --> 00:10:57,285 - Those punches he’s using 289 00:10:57,408 --> 00:10:59,158 are not made to go through hot metal. 290 00:10:59,243 --> 00:11:02,493 We have drifts in here that are specifically made 291 00:11:02,580 --> 00:11:04,370 to punch holes in steel. 292 00:11:05,416 --> 00:11:06,796 - [bleep]. 293 00:11:06,918 --> 00:11:09,338 As I’m trying to drift this hole, the punch breaks. 294 00:11:09,420 --> 00:11:11,090 So I’m feeling a little bit frustrated. 295 00:11:11,214 --> 00:11:13,924 But I’ve got to make it work, so I grab another. 296 00:11:14,008 --> 00:11:15,178 [bleep]. 297 00:11:15,259 --> 00:11:16,419 It breaks instantly. 298 00:11:16,510 --> 00:11:17,630 - Oh no. 299 00:11:17,762 --> 00:11:19,642 - Well, now, Dan needs to get another punch. 300 00:11:19,764 --> 00:11:22,514 - So I grab a third punch. 301 00:11:22,600 --> 00:11:24,100 And that one breaks as well. 302 00:11:24,227 --> 00:11:25,607 So I’m just, you know, 303 00:11:25,728 --> 00:11:27,438 getting a little bit frustrated with it. 304 00:11:27,563 --> 00:11:30,353 - Dan’s having a lot of trouble trying to get those holes in. 305 00:11:30,441 --> 00:11:32,731 - That punch is spreading out as opposed to going through. 306 00:11:32,818 --> 00:11:35,738 - If I’m not able to punch these holes, 307 00:11:35,821 --> 00:11:37,741 I would definitely be sent home. 308 00:11:37,823 --> 00:11:39,613 I just don’t know what to do. 309 00:11:39,700 --> 00:11:40,610 [bleep]. 310 00:11:44,372 --> 00:11:46,122 - There’s a blackout, and there’s no power tools. 311 00:11:46,207 --> 00:11:48,337 So I’m trying to get these holes punched by hand. 312 00:11:48,459 --> 00:11:49,579 [bleep]. 313 00:11:49,669 --> 00:11:51,579 And these punches keep breaking. 314 00:11:51,671 --> 00:11:54,091 If I’m not able to punch these holes, 315 00:11:54,173 --> 00:11:56,053 I could definitely get eliminated. 316 00:11:56,133 --> 00:11:58,763 But I’m not just gonna give up or throw in the towel. 317 00:11:58,844 --> 00:12:00,514 I’m--I’m gonna keep smashing them in there 318 00:12:00,638 --> 00:12:01,898 till they’re through. 319 00:12:01,973 --> 00:12:03,103 Right on. 320 00:12:03,182 --> 00:12:04,602 So I finally get the punch through. 321 00:12:04,684 --> 00:12:06,314 It’s a little bit of relief, 322 00:12:06,394 --> 00:12:08,064 but I’ve wasted too much time. 323 00:12:08,145 --> 00:12:11,445 - Bladesmiths, you guys have 30 minutes left 324 00:12:11,524 --> 00:12:12,984 before the first elimination. 325 00:12:13,067 --> 00:12:14,777 - Time is running out. 326 00:12:14,860 --> 00:12:16,650 I need to get this thing in the quench tank, 327 00:12:16,737 --> 00:12:17,827 and I’m freaking out. 328 00:12:17,947 --> 00:12:18,997 It’ll have to do. 329 00:12:19,073 --> 00:12:20,403 If I get a warp in the blade, 330 00:12:20,491 --> 00:12:22,321 I’m not gonna have enough time to fix it. 331 00:12:22,410 --> 00:12:24,780 - With just a bit of time on the clock, 332 00:12:24,870 --> 00:12:27,200 quench the blade, make sure it’s straight, 333 00:12:27,331 --> 00:12:29,411 and you can continue to file a hard blade. 334 00:12:29,500 --> 00:12:31,370 It’s definitely gonna be harder to move metal, 335 00:12:31,502 --> 00:12:33,632 but you’re not gonna get anywhere 336 00:12:33,713 --> 00:12:36,503 if you don’t have that blade quenched. 337 00:12:38,050 --> 00:12:40,970 - There we go, three down. Dan’s gonna be the last to go. 338 00:12:41,053 --> 00:12:44,013 Bladesmiths, you have 15 minutes left. 339 00:12:44,098 --> 00:12:44,978 - I’m running behind schedule. 340 00:12:45,057 --> 00:12:46,267 We’ll see. 341 00:12:46,350 --> 00:12:48,310 I’ve wasted too much time punching holes. 342 00:12:48,394 --> 00:12:50,104 So I’m gonna take my chances 343 00:12:50,187 --> 00:12:53,657 and skip normalizing in order to save time. 344 00:12:53,733 --> 00:12:55,943 The main thing I’m worried about with cutting corners 345 00:12:56,027 --> 00:12:59,447 with normalizing is that there could be cracks. 346 00:12:59,530 --> 00:13:02,490 - You have two minutes remaining. 347 00:13:03,576 --> 00:13:04,706 There we go. 348 00:13:04,785 --> 00:13:06,375 All right, all four blades are quenched. 349 00:13:06,495 --> 00:13:08,085 Dan’s in the oil. 350 00:13:08,205 --> 00:13:09,835 - A little twist. 351 00:13:09,915 --> 00:13:12,875 I do see a small twist at the tip of the blade, 352 00:13:12,960 --> 00:13:14,880 so I’m going to try to straighten it out 353 00:13:14,962 --> 00:13:16,132 with light taps. 354 00:13:16,213 --> 00:13:18,303 There’s definitely a risk to doing that, 355 00:13:18,382 --> 00:13:20,922 ’cause now there could be cracking as a result. 356 00:13:21,052 --> 00:13:24,012 I hope this decision doesn’t have any major lash back. 357 00:13:24,096 --> 00:13:28,436 - Five, four, three, two, one. 358 00:13:28,559 --> 00:13:30,269 Bladesmiths, put down your tools. 359 00:13:30,394 --> 00:13:33,064 The first round of this blackout competition’s over. 360 00:13:33,147 --> 00:13:36,117 - I’m very proud of the work that I’ve done in three hours 361 00:13:36,233 --> 00:13:38,573 without having a press or a power hammer. 362 00:13:38,694 --> 00:13:41,194 But I’m most nervous in the critique about something 363 00:13:41,280 --> 00:13:43,400 I’m not able to see in the dark. 364 00:13:43,491 --> 00:13:45,661 - Bladesmiths, congratulations. 365 00:13:45,743 --> 00:13:47,703 You guys made it through the first three hours 366 00:13:47,787 --> 00:13:50,127 of this blackout competition with no electricity, 367 00:13:50,247 --> 00:13:52,297 solely manpower. 368 00:13:52,416 --> 00:13:54,256 The time has come for the first critique. 369 00:13:54,335 --> 00:13:55,925 Dan, you’re up first. You ready? 370 00:13:56,045 --> 00:13:57,675 - Absolutely. - Please present your work. 371 00:14:00,383 --> 00:14:01,593 - All right, Dan. 372 00:14:01,717 --> 00:14:05,227 You did a real fine job moving that steel by hand. 373 00:14:05,304 --> 00:14:06,644 You were just chugging right along. 374 00:14:06,764 --> 00:14:08,604 But you did rush the heat treat. 375 00:14:08,724 --> 00:14:10,224 That concerns me. 376 00:14:10,309 --> 00:14:12,389 But everything else, good job. 377 00:14:12,478 --> 00:14:13,778 - Thank you. 378 00:14:13,896 --> 00:14:15,276 - All right, Sean, you’re up. You’re ready? 379 00:14:15,398 --> 00:14:16,948 - Yes, sir. - Please present your work. 380 00:14:19,944 --> 00:14:20,984 - All right, Sean. 381 00:14:21,112 --> 00:14:23,902 Got a nice profile with your blade. 382 00:14:23,989 --> 00:14:25,949 But your curvature that you have here, 383 00:14:26,075 --> 00:14:27,785 it’s got to flow a little bit more 384 00:14:27,868 --> 00:14:30,238 so that it doesn’t get hung up. 385 00:14:30,329 --> 00:14:31,739 If you go to the second round, 386 00:14:31,831 --> 00:14:33,581 you just got to smoothen that out and refine it. 387 00:14:33,666 --> 00:14:36,586 But overall, good job. - Thank you, sir. 388 00:14:36,669 --> 00:14:38,539 - Alright, JD, you ready? - I am, sir. 389 00:14:38,629 --> 00:14:39,879 - Please present your work. 390 00:14:42,675 --> 00:14:45,475 - All right, so JD, good job. 391 00:14:45,553 --> 00:14:48,593 The biggest concern I have with your blade is the profile. 392 00:14:48,681 --> 00:14:51,261 Right now, you’ve got this large belly 393 00:14:51,350 --> 00:14:52,510 way at the front of this blade 394 00:14:52,643 --> 00:14:54,773 that may affect the way it cuts. 395 00:14:54,854 --> 00:14:57,904 Handle-wise, it’s sticking up above everything. 396 00:14:57,982 --> 00:14:59,982 Kind of drives everything back into the hand. 397 00:15:00,067 --> 00:15:01,907 But the blade is straight. 398 00:15:01,986 --> 00:15:02,866 Good job. 399 00:15:02,987 --> 00:15:04,157 - Thank you, sir. 400 00:15:04,238 --> 00:15:05,538 - Finally, we got Ron. You ready? 401 00:15:05,656 --> 00:15:06,576 - Moving forward. 402 00:15:06,657 --> 00:15:08,167 - Please present your work. 403 00:15:11,162 --> 00:15:12,282 - All right, Ron. 404 00:15:12,371 --> 00:15:14,951 First up, nice hammer strikes in there. 405 00:15:15,040 --> 00:15:18,290 Now your recurve here, you have a belly 406 00:15:18,377 --> 00:15:21,137 that’s prominent to where I can’t decide whether 407 00:15:21,213 --> 00:15:23,133 I’m gonna cut with this or cut with this belly. 408 00:15:23,215 --> 00:15:24,965 If you move forward, I’d like to see 409 00:15:25,050 --> 00:15:27,510 your recurve here be much more subtle. 410 00:15:27,595 --> 00:15:30,185 But overall, good job. 411 00:15:30,264 --> 00:15:33,474 - Gentlemen, you guys all brought forward blades 412 00:15:33,559 --> 00:15:34,969 that met our parameters. 413 00:15:35,060 --> 00:15:36,890 But, guys, in this competition, only three of you 414 00:15:37,021 --> 00:15:38,391 can join us in the second round. 415 00:15:38,522 --> 00:15:39,692 And although difficult, 416 00:15:39,773 --> 00:15:42,483 our judges did make a common decision. 417 00:15:42,568 --> 00:15:44,408 The bladesmith leaving The Forge is... 418 00:15:44,528 --> 00:15:47,188 [dramatic music] 419 00:15:47,323 --> 00:15:50,203 JD, unfortunately, your blade didn’t make the cut, 420 00:15:50,326 --> 00:15:51,996 and J.’s gonna tell you why. 421 00:15:52,077 --> 00:15:54,037 - JD, that was a really tough challenge 422 00:15:54,163 --> 00:15:55,873 and we had to pick out little differences. 423 00:15:55,956 --> 00:15:59,256 But the reprofiling of your blade is going to have 424 00:15:59,376 --> 00:16:01,046 more work for you than your other smiths. 425 00:16:01,170 --> 00:16:02,250 That’s why we’re sending you home. 426 00:16:02,379 --> 00:16:04,169 - I understand. - Well, JD, you showed us 427 00:16:04,256 --> 00:16:06,386 you’re a talented smith, but unfortunately 428 00:16:06,467 --> 00:16:07,557 your time in this competition has ended. 429 00:16:07,676 --> 00:16:08,926 I’m gonna have to ask you to please 430 00:16:09,053 --> 00:16:10,343 step off the Forge floor. 431 00:16:11,597 --> 00:16:12,727 - Even though my kids said, 432 00:16:12,848 --> 00:16:14,388 "Just don’t get out in the first round," 433 00:16:14,475 --> 00:16:16,855 I know that my kids will always be proud of me. 434 00:16:16,936 --> 00:16:19,736 But when I get home, I am definitely 435 00:16:19,813 --> 00:16:21,273 gonna remember to pay my electric bill 436 00:16:21,398 --> 00:16:24,018 so I never have to forge in the dark again. 437 00:16:26,445 --> 00:16:27,695 - All right, gentlemen, congratulations. 438 00:16:27,780 --> 00:16:29,070 The three of you are joining us 439 00:16:29,156 --> 00:16:30,326 in the second round of this competition 440 00:16:30,407 --> 00:16:31,957 where you’re adding handles to your blades, 441 00:16:32,076 --> 00:16:33,576 turning them into fully functioning weapons. 442 00:16:33,661 --> 00:16:35,531 But unfortunately, as you know, 443 00:16:35,621 --> 00:16:37,041 the power is still out in The Forge. 444 00:16:37,122 --> 00:16:40,372 So all the tools on the Forge floor are out of commission. 445 00:16:40,459 --> 00:16:42,499 But, thankfully for you, 446 00:16:42,586 --> 00:16:44,086 I was able to scrounge these up. 447 00:16:45,589 --> 00:16:46,749 Gentlemen, we’ve got some battery-powered 448 00:16:46,840 --> 00:16:48,920 drills and angle grinders for you to use 449 00:16:49,009 --> 00:16:50,009 during the second round. 450 00:16:50,094 --> 00:16:52,724 - We get power equipment now, yes. 451 00:16:52,805 --> 00:16:55,265 Drills, grinders, yay! 452 00:16:55,349 --> 00:16:56,719 That makes me happy. 453 00:16:56,809 --> 00:16:57,849 - Now as far as testing goes, 454 00:16:57,935 --> 00:16:59,775 you’re still going into that blind. 455 00:16:59,853 --> 00:17:02,603 But I will tell you, it’s gonna be very difficult. 456 00:17:02,731 --> 00:17:05,021 So work as hard as you can during this entire round. 457 00:17:05,109 --> 00:17:06,939 Gentlemen, you only have two hours 458 00:17:07,069 --> 00:17:08,779 on the clock to complete your blades. 459 00:17:08,904 --> 00:17:11,284 Good luck, because that time starts now. 460 00:17:11,365 --> 00:17:15,455 [intense rock music] 461 00:17:15,578 --> 00:17:17,538 Seems like giving these guys the battery powered tools 462 00:17:17,621 --> 00:17:19,291 makes things a little bit easier for them. 463 00:17:19,373 --> 00:17:20,913 - There’s nothing easy about doing this. 464 00:17:21,000 --> 00:17:23,080 I mean, having those power tools, yeah, 465 00:17:23,168 --> 00:17:25,668 it’s definitely an advantage over having to file, 466 00:17:25,796 --> 00:17:28,926 but it’s still a lot of work that’s got to happen out there. 467 00:17:29,008 --> 00:17:30,468 - As soon as the round starts, 468 00:17:30,551 --> 00:17:32,261 I know that the first thing I want to get on this knife 469 00:17:32,344 --> 00:17:33,554 is a handle. 470 00:17:33,637 --> 00:17:35,647 Trying to find something that I recognize 471 00:17:35,723 --> 00:17:38,263 in this tiny spotlight is very difficult. 472 00:17:38,350 --> 00:17:40,310 - The first round, forging in the dark, 473 00:17:40,394 --> 00:17:42,104 you had all these things that give you light. 474 00:17:42,187 --> 00:17:43,857 - It’s even darker in this round than round one. 475 00:17:43,981 --> 00:17:47,271 - My eyes are immediately drawn to two blocks of maple 476 00:17:47,359 --> 00:17:49,649 because it’s a generally reliable hardwood. 477 00:17:49,737 --> 00:17:51,407 But, they are massive. 478 00:17:51,488 --> 00:17:53,608 If this thing doesn’t index in the judges’ hands, 479 00:17:53,699 --> 00:17:54,989 well, they’re gonna notice. 480 00:17:55,075 --> 00:17:57,205 So I got to start hogging away material fast. 481 00:17:57,328 --> 00:18:00,498 Doing this by hand would be much harder to do. 482 00:18:00,623 --> 00:18:02,333 - Sean’s already got the scales on. 483 00:18:02,458 --> 00:18:04,258 - That is a smart move. 484 00:18:06,378 --> 00:18:09,128 - Praise Thor’s hairy chest-- I have a grinder. 485 00:18:09,214 --> 00:18:11,174 So immediately, I started working on 486 00:18:11,300 --> 00:18:13,300 readdressing my recurve. 487 00:18:13,385 --> 00:18:15,015 If we didn’t have power tools, 488 00:18:15,137 --> 00:18:17,727 I would have had to file by hand. 489 00:18:17,848 --> 00:18:20,008 It is amazing having a grinder. 490 00:18:20,100 --> 00:18:21,600 - What Ron’s doing right now that I like 491 00:18:21,685 --> 00:18:23,685 is he’ll do a few passes with the angle grinder 492 00:18:23,812 --> 00:18:25,772 and then put his hand on the blade 493 00:18:25,856 --> 00:18:27,696 to see how hot it’s getting. 494 00:18:27,816 --> 00:18:30,736 So he’s keeping an eye on not losing his temper--smart move. 495 00:18:30,861 --> 00:18:32,321 - That’ll work. 496 00:18:35,074 --> 00:18:36,914 - Thank goodness these battery powered tools 497 00:18:37,034 --> 00:18:40,244 are going to allow me to have a chance of finishing my knife 498 00:18:40,371 --> 00:18:41,491 within these two hours. 499 00:18:41,580 --> 00:18:43,160 My biggest concern is definitely 500 00:18:43,248 --> 00:18:44,578 the warp in the cutting edge. 501 00:18:44,708 --> 00:18:46,828 So that’s the first thing I’m going to address. 502 00:18:46,919 --> 00:18:48,459 - What are some things that Dan can do 503 00:18:48,545 --> 00:18:50,175 to straighten that tip out? 504 00:18:50,255 --> 00:18:51,925 - Well, he’s got enough material there 505 00:18:52,049 --> 00:18:54,509 that he can grind a lot of that straight. 506 00:18:54,593 --> 00:18:56,843 - My edge is just about as straight as I could 507 00:18:56,929 --> 00:18:58,799 possibly get it, and I need to move on. 508 00:18:58,889 --> 00:19:01,349 - All right, bladesmiths, you guys have 90 minutes left 509 00:19:01,433 --> 00:19:03,683 in the second round. 510 00:19:03,769 --> 00:19:05,349 - Once the handle material is on, 511 00:19:05,437 --> 00:19:07,607 I can start focusing on my next steps. 512 00:19:07,731 --> 00:19:10,191 Doug told me that he would like to see that cutting edge 513 00:19:10,275 --> 00:19:11,655 be brought down a little bit more. 514 00:19:11,735 --> 00:19:13,985 I have to be very careful with this process. 515 00:19:14,071 --> 00:19:16,741 If I end up slipping and taking off too much material 516 00:19:16,824 --> 00:19:18,324 from a place that can’t afford it, 517 00:19:18,409 --> 00:19:20,199 I don’t think I can come back from that. 518 00:19:20,285 --> 00:19:21,535 Hell yeah. 519 00:19:21,620 --> 00:19:23,540 At this point, I’m starting to feel really good 520 00:19:23,622 --> 00:19:24,752 about how it looks. 521 00:19:24,832 --> 00:19:27,252 I think I’m about ready to sharpen. 522 00:19:28,585 --> 00:19:29,715 - I’ve got the pin fitted. 523 00:19:29,795 --> 00:19:31,505 I’ve got the scales roughly shaped. 524 00:19:31,588 --> 00:19:33,668 So now I put an Ito wrap on there. 525 00:19:33,757 --> 00:19:36,727 I do a lot of Ito wraps ’cause I love how they feel 526 00:19:36,802 --> 00:19:38,262 and I love the aesthetics of them. 527 00:19:38,345 --> 00:19:40,435 - You don’t do the cord wrap properly, 528 00:19:40,514 --> 00:19:43,434 and the cord wrap starts to move on that core material, 529 00:19:43,517 --> 00:19:46,437 you’ve got a handle that’s coming loose. 530 00:19:46,562 --> 00:19:49,772 - 100% of the time I feel the urge to be creating stuff 531 00:19:49,857 --> 00:19:52,567 whether it’s tattooing myself, making knives. 532 00:19:52,651 --> 00:19:54,861 I just always have to have something in my hands 533 00:19:54,945 --> 00:19:56,495 and be creating something. 534 00:19:56,613 --> 00:19:57,993 I finish the Ito wrap. 535 00:19:58,115 --> 00:20:00,365 It’s not as clean as I would have liked it, 536 00:20:00,451 --> 00:20:02,571 but it feels pretty good in the hand. 537 00:20:04,830 --> 00:20:08,120 - For the handle, I wanted to find a synthetic material 538 00:20:08,208 --> 00:20:11,248 because I’m used to using it and I have no idea 539 00:20:11,336 --> 00:20:14,426 what the testing is, so I want something I’m familiar with. 540 00:20:14,506 --> 00:20:16,386 - That’s the wrong tool. 541 00:20:16,467 --> 00:20:18,427 - You got hammers all over the shop, 542 00:20:18,510 --> 00:20:20,430 Ron’s using the C clamp. 543 00:20:20,512 --> 00:20:22,262 [groaning] 544 00:20:22,347 --> 00:20:23,767 - Uh-oh. - Not good. 545 00:20:23,849 --> 00:20:25,509 - Ron’s handle material just snapped in half. 546 00:20:25,642 --> 00:20:28,892 - At this point, I am terrified. 547 00:20:28,979 --> 00:20:31,809 I don’t know how much time we have left, 548 00:20:31,940 --> 00:20:34,690 and I have to start over. 549 00:20:34,818 --> 00:20:35,818 So I’m frantic. 550 00:20:35,903 --> 00:20:38,113 [grunts] No! 551 00:20:41,825 --> 00:20:43,455 - [groaning] 552 00:20:43,535 --> 00:20:44,785 - Uh-oh. - Not good. 553 00:20:44,870 --> 00:20:47,620 - Ron’s handle material just snapped in half. 554 00:20:47,706 --> 00:20:49,666 - I have to put scales on this. 555 00:20:49,792 --> 00:20:50,752 So I’m frantic. 556 00:20:50,834 --> 00:20:54,004 I decide to change the game plan. 557 00:20:54,129 --> 00:20:57,089 I am not going to use synthetic material. 558 00:20:57,174 --> 00:20:58,594 I’m going to use wood. 559 00:20:58,675 --> 00:21:00,595 - Bladesmiths, you have 30 minutes left. 560 00:21:00,677 --> 00:21:03,397 Ron is on his second set of handle scales. 561 00:21:03,514 --> 00:21:04,854 Let’s see if this one’s a charm. 562 00:21:04,932 --> 00:21:07,432 - I’m starting over. I am very nervous. 563 00:21:07,518 --> 00:21:12,778 I don’t know if I can complete this in the time left. 564 00:21:12,856 --> 00:21:15,616 - I am in love with the shape of this knife, 565 00:21:15,692 --> 00:21:16,942 but it has to be sharp enough 566 00:21:17,027 --> 00:21:18,117 for whatever test they come up with. 567 00:21:18,195 --> 00:21:21,035 - How hard is it, really, to get that fine edge 568 00:21:21,114 --> 00:21:23,284 with an angle grinder? - Hard. 569 00:21:23,367 --> 00:21:24,877 One of the things these smiths ought to do 570 00:21:24,993 --> 00:21:26,413 is start using the stones. 571 00:21:26,537 --> 00:21:29,047 That way they’re gonna have a nice clean smooth edge 572 00:21:29,164 --> 00:21:32,464 as opposed to a 36-grit flat wheel edge. 573 00:21:32,543 --> 00:21:35,213 - I use the whetstone because we still don’t have 574 00:21:35,337 --> 00:21:37,967 power for the grinders, and I really don’t want to 575 00:21:38,048 --> 00:21:40,208 risk overheating it with an angle grinder. 576 00:21:40,342 --> 00:21:42,052 She shaves hair. 577 00:21:42,135 --> 00:21:43,725 I am ecstatic. 578 00:21:43,846 --> 00:21:45,976 If a blade is sharp enough to pull this hair off 579 00:21:46,056 --> 00:21:46,976 your arm, you know that it’s gonna 580 00:21:47,057 --> 00:21:48,727 be sharp enough to cut anything. 581 00:21:48,851 --> 00:21:50,971 Okay, we’re real close. 582 00:21:51,061 --> 00:21:53,141 - I need to get a sharp blade, 583 00:21:53,230 --> 00:21:55,650 but I’m not super comfortable with whetstones. 584 00:21:55,732 --> 00:21:57,522 - Dan grabbed belts. 585 00:21:57,609 --> 00:21:59,479 We don’t have the belt grinders going, 586 00:21:59,570 --> 00:22:01,400 but we didn’t say he couldn’t use the equipment 587 00:22:01,488 --> 00:22:02,738 that goes on them. - Shoe shining with those belts 588 00:22:02,865 --> 00:22:04,245 is a great idea. - Yep. 589 00:22:04,366 --> 00:22:07,326 - I’m trying to slack grind as much as possible. 590 00:22:07,411 --> 00:22:09,531 I feel more confident that that would build up 591 00:22:09,621 --> 00:22:10,871 a micro-cutting edge. 592 00:22:10,956 --> 00:22:13,666 Hopefully it functions well under testing. 593 00:22:13,750 --> 00:22:17,420 - My new handle goes on faster than I had thought, 594 00:22:17,546 --> 00:22:19,046 which makes me happy. 595 00:22:19,131 --> 00:22:22,051 But I still want to put a good edge on the blade. 596 00:22:22,134 --> 00:22:24,844 I start using pieces of sandpaper 597 00:22:24,928 --> 00:22:27,548 to start profiling the edge a little bit. 598 00:22:27,639 --> 00:22:29,679 It’s incredibly slow, 599 00:22:29,766 --> 00:22:31,526 but I think it’s almost there. 600 00:22:32,895 --> 00:22:36,105 - Would you look at that, guys, the power’s back on. 601 00:22:36,231 --> 00:22:37,351 Just in time too. 602 00:22:37,441 --> 00:22:41,611 Five, four, three, two, one. 603 00:22:41,695 --> 00:22:43,195 Bladesmiths, put down your tools. 604 00:22:43,280 --> 00:22:45,280 This round is officially over. 605 00:22:45,407 --> 00:22:46,617 Very well done. 606 00:22:46,700 --> 00:22:49,700 - I am elated. I am excited. 607 00:22:49,786 --> 00:22:54,876 I had to start over, and I still made it in time. 608 00:22:54,958 --> 00:22:57,748 [tense music] 609 00:22:57,836 --> 00:22:59,886 - All right gentlemen, it’s time for the strength test. 610 00:22:59,963 --> 00:23:01,553 And sticking with our blackout theme, 611 00:23:01,632 --> 00:23:02,882 the flashlight chop. 612 00:23:04,468 --> 00:23:05,678 Dan, you’re up first, you ready? 613 00:23:05,802 --> 00:23:08,392 - Absolutely. - Okay. 614 00:23:09,431 --> 00:23:10,891 - The moment I see all the flashlights, 615 00:23:10,974 --> 00:23:12,644 I’m thinking this is gonna be a little more brutal 616 00:23:12,768 --> 00:23:14,228 than I was expecting. 617 00:23:14,311 --> 00:23:17,231 I have no idea what my blade is gonna do 618 00:23:17,314 --> 00:23:18,604 up against those flashlights. 619 00:23:20,484 --> 00:23:23,944 [intense music] 620 00:23:24,029 --> 00:23:30,739 ♪ ♪ 621 00:23:37,334 --> 00:23:39,624 [suspenseful music] 622 00:23:39,711 --> 00:23:42,921 - Right, so, Dan, that’s a really nicely designed blade. 623 00:23:43,006 --> 00:23:44,756 As far as how well your blade held up, 624 00:23:44,841 --> 00:23:46,971 it’s still true, it’s still got an edge. 625 00:23:47,052 --> 00:23:49,132 Might have a little bit of dulling right here. 626 00:23:49,221 --> 00:23:51,261 But you do have a crack in the blade. 627 00:23:51,348 --> 00:23:52,858 When I run my finger on this side of the blade, 628 00:23:52,975 --> 00:23:54,515 I can feel it. 629 00:23:54,643 --> 00:23:57,683 The edge of the blade has moved just slightly away 630 00:23:57,813 --> 00:23:58,853 from that crack. 631 00:23:58,981 --> 00:24:00,941 Beyond that, I think you did a great job. 632 00:24:01,024 --> 00:24:03,194 Well done. - Thank you. 633 00:24:03,276 --> 00:24:04,526 - All right, Sean, your turn, you ready? 634 00:24:04,611 --> 00:24:06,531 - Yes, sir. - Okay. 635 00:24:07,906 --> 00:24:10,366 - I can’t help but feel anything but anxiety. 636 00:24:10,492 --> 00:24:13,622 If I take any edge rolling, who knows 637 00:24:13,704 --> 00:24:16,504 how I’m gonna hold up in the sharpness test? 638 00:24:18,542 --> 00:24:23,382 ♪ ♪ 639 00:24:36,601 --> 00:24:40,141 - All right, Sean, your blade, still straight, 640 00:24:40,230 --> 00:24:41,390 still in one piece. 641 00:24:41,481 --> 00:24:43,231 And I can feel a lot of sharp parts on it, 642 00:24:43,358 --> 00:24:44,688 but you’ve lost some edge. 643 00:24:44,776 --> 00:24:47,156 There’s sections of this where I can rub my finger. 644 00:24:47,237 --> 00:24:48,827 But the blade held together. 645 00:24:48,905 --> 00:24:50,575 Nicely done. - Thank you, sir. 646 00:24:50,657 --> 00:24:52,577 - Ron. Ready? 647 00:24:52,659 --> 00:24:54,909 - Make it go dark. - [chuckles] 648 00:24:56,371 --> 00:24:59,001 - I broke my scales trying to get the scales on. 649 00:24:59,082 --> 00:25:00,662 I’m not confident 650 00:25:00,751 --> 00:25:02,081 that they can even make it through testing. 651 00:25:02,210 --> 00:25:04,170 I have to survive this. 652 00:25:04,254 --> 00:25:06,554 Survive or go home. 653 00:25:06,631 --> 00:25:09,091 ♪ ♪ 654 00:25:12,846 --> 00:25:15,016 - I broke my scales trying to get the handle on it 655 00:25:15,098 --> 00:25:17,138 so I hope that they survive this. 656 00:25:19,269 --> 00:25:23,309 [driving rock music] 657 00:25:23,440 --> 00:25:29,900 ♪ ♪ 658 00:25:35,952 --> 00:25:37,162 - Ron, I was really worried about your handle 659 00:25:37,287 --> 00:25:39,167 going into testing ’cause of the trouble you had 660 00:25:39,289 --> 00:25:41,869 with the broken scales, but I was wrong. 661 00:25:41,958 --> 00:25:43,288 It’s a very comfortable handle. 662 00:25:43,376 --> 00:25:45,136 As far as your edge goes, 663 00:25:45,212 --> 00:25:46,422 I can run my fingernail down this 664 00:25:46,505 --> 00:25:47,845 and not feel any damage at all. 665 00:25:47,964 --> 00:25:51,174 Really, really good job. - Thank you. 666 00:25:53,512 --> 00:25:55,802 - All right, bladesmiths, this is the sharpness test-- 667 00:25:55,889 --> 00:25:58,639 the fire blanket slice. 668 00:25:58,767 --> 00:26:00,397 Dan, you’re up first. You ready for this? 669 00:26:00,477 --> 00:26:02,777 - Absolutely. - Let’s do this. 670 00:26:06,900 --> 00:26:11,190 [intense music] 671 00:26:11,321 --> 00:26:18,781 ♪ ♪ 672 00:26:26,545 --> 00:26:28,175 Right, Dan, let’s talk about your blade here. 673 00:26:28,255 --> 00:26:29,885 The front section right here is very sharp, 674 00:26:30,006 --> 00:26:33,096 but that one area where you have this little crack, 675 00:26:33,176 --> 00:26:36,186 it did give us some of these jagged edge cuts. 676 00:26:36,263 --> 00:26:38,803 And, of course, this area right underneath the belly, 677 00:26:38,890 --> 00:26:40,680 on the last cut, that’s the reason 678 00:26:40,767 --> 00:26:43,227 why it didn’t cut all the way because it’s dull in this area. 679 00:26:43,353 --> 00:26:47,603 But overall, your weapon, it will cut. 680 00:26:47,691 --> 00:26:49,401 All right, Sean, your turn, you ready? 681 00:26:49,526 --> 00:26:51,236 - Yes, sir. - Let’s do this. 682 00:26:51,361 --> 00:26:58,281 ♪ ♪ 683 00:27:15,135 --> 00:27:18,595 All right, Sean, your edge-- some sections of this 684 00:27:18,722 --> 00:27:21,262 didn’t cut where it meets a dull area, 685 00:27:21,391 --> 00:27:23,851 but where the edges are sharp--it will cut. 686 00:27:23,935 --> 00:27:25,275 - Thank you, sir. 687 00:27:25,395 --> 00:27:26,945 - Ron, your turn. You ready? 688 00:27:27,063 --> 00:27:28,693 - Yes, I am. - Let’s do this. 689 00:27:30,775 --> 00:27:33,695 - My wife told me that if I made it to the second round 690 00:27:33,778 --> 00:27:35,738 of testing, and if Doug does not say, 691 00:27:35,822 --> 00:27:38,112 "It will cut," I am not to come home. 692 00:27:38,241 --> 00:27:39,491 [chuckles] 693 00:27:39,576 --> 00:27:41,576 So I hope my blade cuts well. 694 00:27:45,498 --> 00:27:48,788 [dramatic music] 695 00:27:48,919 --> 00:27:54,549 ♪ ♪ 696 00:28:02,015 --> 00:28:04,815 [tense percussive music] 697 00:28:04,935 --> 00:28:08,945 - All right, Ron, your edge, because it’s a tooth grind, 698 00:28:09,022 --> 00:28:11,022 it wasn’t a razor cut on the last slash. 699 00:28:11,107 --> 00:28:12,527 But the rest of the cuts... 700 00:28:12,609 --> 00:28:13,819 it will cut. 701 00:28:13,944 --> 00:28:15,944 - Awesome. 702 00:28:16,029 --> 00:28:18,149 [tense music] 703 00:28:18,281 --> 00:28:20,161 - Bladesmiths, I gotta say right off the bat, 704 00:28:20,283 --> 00:28:21,363 it’s been an absolute pleasure 705 00:28:21,451 --> 00:28:23,201 watching all three of you guys work your ways 706 00:28:23,286 --> 00:28:25,336 through a very unique challenge. 707 00:28:25,455 --> 00:28:27,045 Our judges have discussed your blades 708 00:28:27,123 --> 00:28:28,503 and they made a final decision. 709 00:28:28,625 --> 00:28:29,835 The bladesmith leaving The Forge is... 710 00:28:29,960 --> 00:28:32,000 [suspenseful music] 711 00:28:32,128 --> 00:28:35,168 Dan, unfortunately, your blade didn’t make the cut, 712 00:28:35,298 --> 00:28:36,668 and Dave Baker’s gonna tell you why. 713 00:28:36,800 --> 00:28:38,510 - Dan, you designed and built 714 00:28:38,635 --> 00:28:40,515 an absolutely beautiful blade by hand, 715 00:28:40,637 --> 00:28:42,187 and I’m really impressed with your work. 716 00:28:42,305 --> 00:28:44,265 But it looks to me like that heat treat 717 00:28:44,349 --> 00:28:45,809 was too high on that W1 718 00:28:45,892 --> 00:28:48,352 and that crack formed, and that’s a structural issue 719 00:28:48,478 --> 00:28:50,138 that your competitors just don’t have. 720 00:28:50,272 --> 00:28:52,352 That’s why we’re letting you go. 721 00:28:52,482 --> 00:28:54,232 - Dan, you’re an unbelievably talented smith. 722 00:28:54,317 --> 00:28:55,487 It’s been a pleasure watching you work, 723 00:28:55,568 --> 00:28:57,028 but unfortunately, I’m gonna have to ask you 724 00:28:57,153 --> 00:28:58,073 to please step off the Forge floor. 725 00:28:58,154 --> 00:28:59,154 - Thank you. - Thank you. 726 00:28:59,239 --> 00:29:01,029 - Good job, Dan. 727 00:29:01,157 --> 00:29:02,867 - I absolutely agree with the judges’ decision. 728 00:29:02,993 --> 00:29:05,243 But I had a lot of fun in this competition. 729 00:29:05,328 --> 00:29:07,448 I’m just not a big grinner, 730 00:29:07,539 --> 00:29:10,369 but I’m certainly having a good time. 731 00:29:10,500 --> 00:29:12,500 [chuckles] 732 00:29:14,838 --> 00:29:16,258 - Sean, Ron, congratulations. 733 00:29:16,339 --> 00:29:17,999 Your hard work has paid off and you are both moving forward 734 00:29:18,091 --> 00:29:20,091 in the third and final rounds of this competition. 735 00:29:20,176 --> 00:29:21,936 Now at this point, you get to go back 736 00:29:22,012 --> 00:29:23,722 to your home forges for four days, 737 00:29:23,847 --> 00:29:26,727 using your tools and your electricity to build this.... 738 00:29:26,850 --> 00:29:29,390 ♪ ♪ 739 00:29:31,187 --> 00:29:32,567 The Sword of Mercy. 740 00:29:32,689 --> 00:29:34,099 - Whew. 741 00:29:35,191 --> 00:29:37,521 - The Sword of Mercy, also known as Curtana, 742 00:29:37,610 --> 00:29:40,440 has been used as a coronation sword since the Middle Ages. 743 00:29:40,530 --> 00:29:41,990 The ceremonial blade 744 00:29:42,073 --> 00:29:44,283 is defined by its square-blunted tip. 745 00:29:44,367 --> 00:29:46,247 Legend has it, the sword was broken off 746 00:29:46,369 --> 00:29:48,659 by an angel to prevent a wrongful killing 747 00:29:48,747 --> 00:29:51,127 and therefore symbolizes the mercy it’s named for. 748 00:29:51,207 --> 00:29:52,717 To this day, this benevolent blade 749 00:29:52,792 --> 00:29:55,252 is one of the crown jewels of the United Kingdom 750 00:29:55,378 --> 00:29:56,918 and is still in use in coronations 751 00:29:57,047 --> 00:29:58,427 with kings and queens today, 752 00:29:58,548 --> 00:30:00,628 although even commoners can see it on display 753 00:30:00,717 --> 00:30:03,227 in the Jewel House at the Tower of London. 754 00:30:03,345 --> 00:30:06,435 - Your blades measure from tip to where the cutting edge ends, 755 00:30:06,556 --> 00:30:09,856 and a straight line needs to be between 29 and 31 inches. 756 00:30:09,934 --> 00:30:13,274 Needs to be double-edged, have a blunt, flattened tip. 757 00:30:13,396 --> 00:30:15,236 - The most interesting thing about this sword 758 00:30:15,315 --> 00:30:16,605 is the blunt tip. 759 00:30:16,733 --> 00:30:19,523 I’ve never made a sword with a blunt tip. 760 00:30:19,611 --> 00:30:21,901 So I’m very nervous, but I’m equally excited. 761 00:30:21,988 --> 00:30:23,738 - One of you guys is gonna leave here with the title 762 00:30:23,823 --> 00:30:26,243 of "Forged in Fire" champion and a check for $10,000. 763 00:30:26,326 --> 00:30:29,456 So good luck, guys. We will see you in four days. 764 00:30:31,247 --> 00:30:33,667 [upbeat rock music] 765 00:30:33,750 --> 00:30:36,290 - Here I am in Castle Rock, Colorado, 766 00:30:36,419 --> 00:30:38,839 back in my half of my mom’s garage. 767 00:30:38,922 --> 00:30:40,962 Today we are making the Sword of Mercy. 768 00:30:41,091 --> 00:30:43,131 That’s a ton of steel. [chuckles] 769 00:30:43,259 --> 00:30:45,629 Doing Damascus was really important to me, 770 00:30:45,762 --> 00:30:47,222 because I knew that at the end of the day 771 00:30:47,305 --> 00:30:48,685 if my blade and my competitor’s blade 772 00:30:48,765 --> 00:30:49,975 performed the same, 773 00:30:50,100 --> 00:30:51,760 it was gonna come down to craftsmanship. 774 00:30:51,851 --> 00:30:54,101 I think this is a solid build of steel. 775 00:30:54,187 --> 00:30:56,567 At the end of the day, I’ve been able to forge out 776 00:30:56,648 --> 00:30:58,818 the rough shape of the blade, but I should be able 777 00:30:58,942 --> 00:31:00,482 to finish early in the morning tomorrow. 778 00:31:00,610 --> 00:31:02,440 We’re getting to a good place. 779 00:31:02,529 --> 00:31:05,819 [rock music] 780 00:31:05,949 --> 00:31:08,819 - Here I am, I’m back in my hometown Eugene, Oregon. 781 00:31:08,952 --> 00:31:11,702 I’m getting ready to build the Sword of Mercy. 782 00:31:11,788 --> 00:31:13,838 The original sword is a Damascus. 783 00:31:13,957 --> 00:31:15,207 It’s a single mono steel. 784 00:31:15,291 --> 00:31:17,331 So since I’m doing an actual reproduction, 785 00:31:17,460 --> 00:31:19,330 I wanna spend as much time as I can 786 00:31:19,462 --> 00:31:21,002 to make sure I’m making this 787 00:31:21,131 --> 00:31:23,461 as historically accurate as I can. 788 00:31:23,550 --> 00:31:26,300 I don’t have a power hammer or a press, 789 00:31:26,386 --> 00:31:29,226 so my biggest challenge is going to be 790 00:31:29,305 --> 00:31:31,395 just getting the shape I want. 791 00:31:31,474 --> 00:31:32,974 That’s good. 792 00:31:33,101 --> 00:31:35,391 In round one and two, we had no power, 793 00:31:35,478 --> 00:31:37,768 so similar to my home build here. 794 00:31:37,856 --> 00:31:40,736 I’m able to move half of the length of the steel 795 00:31:40,817 --> 00:31:42,237 I’m working with. 796 00:31:42,318 --> 00:31:45,528 So tomorrow, it’s gonna move a lot faster, I think. 797 00:31:45,655 --> 00:31:47,865 - Today is day two. 798 00:31:47,991 --> 00:31:49,201 Today, we’re gonna be working on 799 00:31:49,325 --> 00:31:51,035 getting that blade quenched. 800 00:31:51,161 --> 00:31:52,991 Yeah, I’m exactly where I want to be. 801 00:31:53,121 --> 00:31:55,201 It is very weird that the blade does not have a tip. 802 00:31:55,331 --> 00:31:58,161 I’ve never been great at grinding double bevel tips. 803 00:31:58,251 --> 00:32:00,831 So, I was actually kind of happy to see it. 804 00:32:00,920 --> 00:32:03,420 I have this blade forged out to shape 805 00:32:03,506 --> 00:32:05,056 and ready for quench. 806 00:32:05,175 --> 00:32:06,425 The more normalizing cycles I have to do 807 00:32:06,509 --> 00:32:07,919 on this blade, the more I realize 808 00:32:08,011 --> 00:32:10,011 it’s gonna be a bitch to get it all up to temp 809 00:32:10,096 --> 00:32:11,436 and ready for quench. 810 00:32:11,514 --> 00:32:13,434 I’ve never had to quench a blade this big. 811 00:32:13,516 --> 00:32:15,526 This quench is worrying me more and more. 812 00:32:15,602 --> 00:32:17,562 I’m terrified. 813 00:32:17,687 --> 00:32:19,527 There’s not much I can do. I can’t start over. 814 00:32:19,606 --> 00:32:21,906 I’m definitely panicking inside. 815 00:32:22,025 --> 00:32:24,695 [dramatic music] 816 00:32:25,695 --> 00:32:26,735 It’s hard. 817 00:32:26,863 --> 00:32:28,243 The blade is great. 818 00:32:28,364 --> 00:32:29,744 This thing hardened as much as it needed to, 819 00:32:29,866 --> 00:32:31,576 which I am relieved to hear. 820 00:32:31,701 --> 00:32:34,281 That’s a [bleep] victory in my book. 821 00:32:34,370 --> 00:32:36,580 - Day three, morning. 822 00:32:36,706 --> 00:32:38,876 Yesterday, I got my blade done 823 00:32:38,958 --> 00:32:41,078 and finished the handle and the pommel. 824 00:32:41,211 --> 00:32:43,081 So I’m really happy. 825 00:32:43,213 --> 00:32:46,213 My main focus is to get the handguard finished today. 826 00:32:46,299 --> 00:32:49,049 The cruciform guard has some twisting on that. 827 00:32:49,135 --> 00:32:50,845 That can take some time. 828 00:32:50,929 --> 00:32:52,799 So I want to make sure that I had as much time as possible. 829 00:32:52,889 --> 00:32:55,809 So as I’m hammering this out, I’m noticing I’m starting 830 00:32:55,892 --> 00:32:59,602 to get a crack on both sides of where I’m shaping this. 831 00:32:59,729 --> 00:33:02,189 The biggest issue it’s going to have is 832 00:33:02,273 --> 00:33:04,563 on a strength test-- more chance of it breaking. 833 00:33:04,651 --> 00:33:06,611 If the blade fails... 834 00:33:06,736 --> 00:33:08,286 I’m out. 835 00:33:12,075 --> 00:33:13,455 - As I’m hammering out my hand guard... 836 00:33:13,576 --> 00:33:14,826 [bleep]. 837 00:33:14,911 --> 00:33:16,491 I see some cracks have started developing. 838 00:33:16,579 --> 00:33:19,079 This is a nightmare. 839 00:33:19,165 --> 00:33:20,835 I decide I’m going to scrap it. 840 00:33:20,917 --> 00:33:24,047 Two hours has been a waste. 841 00:33:24,921 --> 00:33:27,171 I enjoy being able to hand forge things, 842 00:33:27,257 --> 00:33:29,057 but I need to start making some progress. 843 00:33:29,133 --> 00:33:31,593 I cut the shape that I roughly need, 844 00:33:31,719 --> 00:33:34,179 and it’s looking pretty good. 845 00:33:34,264 --> 00:33:36,224 On the money. Okay, good. 846 00:33:36,307 --> 00:33:39,067 End of day three, and I have all 847 00:33:39,143 --> 00:33:40,733 the different little pieces done. 848 00:33:40,812 --> 00:33:43,392 All in all, I feel really confident. 849 00:33:43,481 --> 00:33:45,521 - Today is day four. 850 00:33:45,608 --> 00:33:47,018 We are in the final stretch. 851 00:33:47,110 --> 00:33:49,730 The first thing I gotta do is the wire wrap. 852 00:33:49,821 --> 00:33:52,201 The wire’s constantly gonna want to unravel on me. 853 00:33:52,282 --> 00:33:54,242 So for the time being, and my plan is to 854 00:33:54,325 --> 00:33:56,415 just kind of brute force it until it starts working. 855 00:33:56,494 --> 00:33:58,534 I’d rather spend this time inventing a time machine 856 00:33:58,621 --> 00:34:00,621 to go kill whoever decided this was a good idea. 857 00:34:00,707 --> 00:34:02,297 Dave Baker is very picky 858 00:34:02,417 --> 00:34:03,967 about the way things feel in his hands. 859 00:34:04,085 --> 00:34:06,135 So I want to make sure this thing feels phenomenal. 860 00:34:06,254 --> 00:34:07,214 I want to give him as little reason 861 00:34:07,297 --> 00:34:08,547 to complain as possible. 862 00:34:08,631 --> 00:34:10,461 Looks kind of cool. 863 00:34:10,550 --> 00:34:13,260 All that’s left is getting everything together. 864 00:34:13,344 --> 00:34:15,434 As long as it holds up, I should do well. 865 00:34:17,473 --> 00:34:18,973 Hell yeah. 866 00:34:20,435 --> 00:34:21,645 - Day four. 867 00:34:21,728 --> 00:34:23,898 Today, I can just focus on 868 00:34:23,980 --> 00:34:25,480 finishing up, sharpening up, 869 00:34:25,607 --> 00:34:28,157 and putting everything together without any hiccups. 870 00:34:28,276 --> 00:34:29,736 So far, so good. 871 00:34:29,819 --> 00:34:31,399 Everything is going right and tight. 872 00:34:31,487 --> 00:34:34,577 Finally at the finish line, it’s done. 873 00:34:34,657 --> 00:34:36,417 I really like the way it looks, 874 00:34:36,492 --> 00:34:41,412 and I think it’ll hold out in the testing. 875 00:34:41,497 --> 00:34:44,087 [tense music] 876 00:34:44,167 --> 00:34:45,797 ♪ ♪ 877 00:34:45,877 --> 00:34:48,337 - Well, Sean, Ron, gentlemen, welcome back to The Forge. 878 00:34:48,463 --> 00:34:50,463 We gave you four days at your home forges 879 00:34:50,548 --> 00:34:52,088 to build your Swords of Mercy. 880 00:34:52,175 --> 00:34:54,845 Now before we get into testing, I want to hear about them. 881 00:34:54,927 --> 00:34:57,307 So Ron, tell us about your blade. 882 00:34:59,057 --> 00:35:00,857 - My blade’s 5160 steel, 883 00:35:00,975 --> 00:35:03,475 brass brush mild-steel fittings, 884 00:35:03,561 --> 00:35:06,521 wire wrap handle and cruciform guard. 885 00:35:06,648 --> 00:35:08,198 - Awesome. Sean, how about you? 886 00:35:10,568 --> 00:35:14,778 - I have 26 layers of 15N20 and 1095. 887 00:35:14,864 --> 00:35:17,074 5160 guard, mild-steel pommel, 888 00:35:17,200 --> 00:35:19,120 and a wire-wrapped maple handle. 889 00:35:19,202 --> 00:35:20,122 - Awesome. 890 00:35:20,203 --> 00:35:21,663 All right, gentlemen, one of you 891 00:35:21,746 --> 00:35:22,666 is gonna be leaving here with the title 892 00:35:22,747 --> 00:35:23,797 of "Forged in Fire" champion 893 00:35:23,873 --> 00:35:25,543 carrying a check for $10,000. 894 00:35:25,667 --> 00:35:27,507 The best way we know how to find out which one of you 895 00:35:27,585 --> 00:35:28,835 will take home the title today-- 896 00:35:28,920 --> 00:35:30,380 by putting them through a few tests. 897 00:35:30,505 --> 00:35:33,465 But first, it’s the KEAL. Doug? 898 00:35:33,549 --> 00:35:35,799 ♪ ♪ 899 00:35:35,885 --> 00:35:38,385 - Bladesmiths, welcome to the KEAL test. 900 00:35:39,889 --> 00:35:41,049 Ron, you’re up first, you ready for this? 901 00:35:41,140 --> 00:35:42,310 - Make some pork chops. 902 00:35:42,392 --> 00:35:44,182 There’s some thick bones in there 903 00:35:44,268 --> 00:35:45,728 that I can be concerned with. 904 00:35:45,853 --> 00:35:48,903 I’m just doing everything I can to maintain composure 905 00:35:49,023 --> 00:35:50,023 at this point. 906 00:35:50,108 --> 00:35:53,488 [intense rock music] 907 00:35:53,569 --> 00:36:00,569 ♪ ♪ 908 00:36:08,543 --> 00:36:11,883 - All right, Ron, let’s talk about your Sword of Mercy here. 909 00:36:11,963 --> 00:36:13,923 These are sharp chops. 910 00:36:14,006 --> 00:36:15,716 Each cut was very deep. 911 00:36:15,800 --> 00:36:18,340 Followed by the nice weight that’s backing up the sword, 912 00:36:18,428 --> 00:36:20,558 it cuts deep into this big carcass. 913 00:36:20,638 --> 00:36:22,758 And of course as you can see, it’s easy to wield 914 00:36:22,890 --> 00:36:25,180 and follow through and control your weapon. 915 00:36:25,268 --> 00:36:26,608 Overall, sir, your weapon... 916 00:36:26,728 --> 00:36:28,028 it will KEAL. 917 00:36:28,104 --> 00:36:29,394 - Yeah! 918 00:36:31,816 --> 00:36:32,866 - All right, Sean, your turn, you ready? 919 00:36:32,942 --> 00:36:34,942 - Yes, sir. - Let’s do this. 920 00:36:35,778 --> 00:36:37,188 - I’m pretty nervous. 921 00:36:37,280 --> 00:36:39,860 I know these pigs can be pretty gnarly to blades, 922 00:36:39,949 --> 00:36:43,449 so I’m just hoping the mind goes clean through. 923 00:36:43,578 --> 00:36:47,088 [intense music] 924 00:36:47,165 --> 00:36:53,965 ♪ ♪ 925 00:37:03,306 --> 00:37:06,226 - All right, Sean, let’s talk about your Sword of Mercy here. 926 00:37:06,309 --> 00:37:08,219 I’m able to hold on to it. 927 00:37:08,311 --> 00:37:10,101 I can tell where the edge is. 928 00:37:10,188 --> 00:37:13,028 But your blade, sir, is not very sharp. 929 00:37:13,149 --> 00:37:15,399 As you can see the first cuts right there, 930 00:37:15,485 --> 00:37:17,575 it’s more from blunt force trauma. 931 00:37:17,653 --> 00:37:20,113 But as you can see with the first sections just here, 932 00:37:20,198 --> 00:37:22,498 you have some spots that are sharp, 933 00:37:22,617 --> 00:37:25,077 and that, sir, is what made your blade... 934 00:37:25,161 --> 00:37:26,281 KEAL. 935 00:37:27,955 --> 00:37:32,425 [tense music] 936 00:37:32,502 --> 00:37:34,962 - Bladesmiths, welcome to our strength test, 937 00:37:35,046 --> 00:37:36,756 the throne chop. 938 00:37:36,839 --> 00:37:37,749 Ron, you’re up first. 939 00:37:37,840 --> 00:37:39,130 You look excited. - Oh yeah. 940 00:37:39,217 --> 00:37:40,177 Let’s overthrow the monarchy. 941 00:37:40,301 --> 00:37:42,261 - Let’s do it. 942 00:37:42,345 --> 00:37:46,265 [intense rock music] 943 00:37:46,349 --> 00:37:53,139 ♪ ♪ 944 00:37:53,231 --> 00:37:56,111 [grunting] 945 00:37:58,903 --> 00:38:04,783 ♪ ♪ 946 00:38:11,666 --> 00:38:14,006 All right, Ron, good job. 947 00:38:14,085 --> 00:38:15,965 Edges are still razor sharp. 948 00:38:16,045 --> 00:38:18,505 But that shock wave’s traveling all the way 949 00:38:18,589 --> 00:38:19,959 down this blade and... 950 00:38:20,049 --> 00:38:22,339 [rattling] your guard’s loose now. 951 00:38:22,426 --> 00:38:24,886 But it was comfortable in the hand. 952 00:38:25,012 --> 00:38:27,512 Good job. - Thank you. 953 00:38:27,598 --> 00:38:29,558 - Sean, how you feeling? 954 00:38:29,684 --> 00:38:30,644 - Awful. 955 00:38:30,726 --> 00:38:31,976 [laughter] 956 00:38:32,061 --> 00:38:33,391 - Let’s hope you feel better in a few minutes. 957 00:38:33,521 --> 00:38:34,851 - Let’s hope. 958 00:38:34,939 --> 00:38:36,349 I’m feeling very nervous going into this test. 959 00:38:36,440 --> 00:38:38,360 J. does not pull any punches 960 00:38:38,442 --> 00:38:40,402 when it comes to swinging these swords. 961 00:38:40,528 --> 00:38:41,908 I’m just hoping that everything holds up. 962 00:38:42,029 --> 00:38:44,819 [dramatic music] 963 00:38:44,907 --> 00:38:50,747 ♪ ♪ 964 00:38:54,458 --> 00:38:55,748 - I’m feeling very nervous. [clank] 965 00:38:55,877 --> 00:38:57,337 J. does not pull any punches 966 00:38:57,420 --> 00:38:59,090 when it comes to swinging these swords. 967 00:38:59,213 --> 00:39:01,883 I’m just hoping that everything holds up. 968 00:39:04,176 --> 00:39:07,766 [intense rock music] 969 00:39:07,889 --> 00:39:14,519 ♪ ♪ 970 00:39:26,449 --> 00:39:29,279 - Good job. - Thank you. 971 00:39:33,122 --> 00:39:35,082 - All right, Sean, it’s all in one piece. 972 00:39:35,166 --> 00:39:36,296 Gotta be proud of that. 973 00:39:36,375 --> 00:39:39,295 Your blade is still straight this way. 974 00:39:39,378 --> 00:39:41,128 Not this way. 975 00:39:41,255 --> 00:39:43,965 Your handle, it’s not loose, 976 00:39:44,050 --> 00:39:45,970 but it’s definitely separated 977 00:39:46,052 --> 00:39:47,552 from the base of the handle now. 978 00:39:47,637 --> 00:39:49,477 But, like I said, it’s still in one piece. 979 00:39:49,597 --> 00:39:51,057 Good job. - Thank you, sir. 980 00:39:55,645 --> 00:39:57,485 - All right, bladesmiths, now it’s time 981 00:39:57,605 --> 00:39:59,485 to find out just how sharp your weapons are. 982 00:39:59,607 --> 00:40:00,487 This is the sharpness test-- 983 00:40:00,566 --> 00:40:03,156 the tapestry slice. 984 00:40:03,277 --> 00:40:04,237 Ron, you’re up first, you ready? 985 00:40:04,320 --> 00:40:05,280 - Oh yeah, let’s make it pretty. 986 00:40:05,363 --> 00:40:06,363 - All right, let’s do it. 987 00:40:06,489 --> 00:40:10,319 [punchy music] 988 00:40:10,451 --> 00:40:17,581 ♪ ♪ 989 00:40:22,171 --> 00:40:24,421 - Well done. - Thank you. 990 00:40:24,507 --> 00:40:27,177 [suspenseful music] 991 00:40:27,301 --> 00:40:29,511 - All right, Ron, first up, 992 00:40:29,595 --> 00:40:31,185 it is loose, 993 00:40:31,263 --> 00:40:34,853 but it did not affect my test. 994 00:40:34,934 --> 00:40:36,184 Overall, sir, your edge... 995 00:40:36,268 --> 00:40:37,178 it will cut. 996 00:40:37,269 --> 00:40:38,809 - Awesome. 997 00:40:38,896 --> 00:40:39,856 - All right, Sean, your turn, you ready? 998 00:40:39,939 --> 00:40:41,849 - Yes, sir. - Let’s do this. 999 00:40:45,528 --> 00:40:52,538 ♪ ♪ 1000 00:40:58,708 --> 00:41:00,718 All right, Sean, around this area right here 1001 00:41:00,793 --> 00:41:02,543 you have some sharp edges. 1002 00:41:02,670 --> 00:41:04,710 So you can see in the first cut here in this tapestry, 1003 00:41:04,797 --> 00:41:06,807 it cut in, but when I’m dragging it through, 1004 00:41:06,882 --> 00:41:08,882 it just stops its cut. 1005 00:41:09,010 --> 00:41:12,130 But, it still did cut so... 1006 00:41:12,221 --> 00:41:13,221 it will cut. 1007 00:41:13,305 --> 00:41:14,725 - Thank you, sir. 1008 00:41:18,686 --> 00:41:20,896 - Well, Bladesmiths, this has been a good competition 1009 00:41:20,980 --> 00:41:22,230 right from the very beginning. 1010 00:41:22,356 --> 00:41:24,236 But as you know, only one of you guys 1011 00:41:24,316 --> 00:41:26,576 can leave here with the title of "Forged in Fire" champion 1012 00:41:26,652 --> 00:41:28,322 carrying a check for $10,000. 1013 00:41:28,404 --> 00:41:30,244 Now our judges discussed your blades, 1014 00:41:30,364 --> 00:41:32,154 and I’m not going to leave you in the dark any longer. 1015 00:41:32,241 --> 00:41:34,911 Today’s "Forged in Fire" champion is... 1016 00:41:35,036 --> 00:41:37,916 [intense musical build-up] 1017 00:41:37,997 --> 00:41:40,257 Ron, congratulations. 1018 00:41:40,332 --> 00:41:42,412 Now, Sean, you fought hard, you’re a talented smith, 1019 00:41:42,501 --> 00:41:44,751 but unfortunately your blade did not make the cut, 1020 00:41:44,837 --> 00:41:46,757 and Doug’s gonna tell you why. 1021 00:41:46,839 --> 00:41:47,999 - Sean, first off, I have to commend you. 1022 00:41:48,090 --> 00:41:50,260 That’s a nice Damascus baton you have there. 1023 00:41:50,342 --> 00:41:52,932 But during our test, your blade took some bends. 1024 00:41:53,054 --> 00:41:56,354 It also underperformed in the KEAL and sharpness test, 1025 00:41:56,432 --> 00:41:57,602 and for those reasons, we’re letting you go. 1026 00:41:57,683 --> 00:41:59,143 - I understand completely. 1027 00:41:59,268 --> 00:42:00,928 - But Sean, we hope you had as much fun 1028 00:42:01,020 --> 00:42:02,350 in this Forge as we had watching you. 1029 00:42:02,438 --> 00:42:04,278 But unfortunately this time, I’m going to have to ask you 1030 00:42:04,398 --> 00:42:05,768 to please step off the Forge floor. 1031 00:42:05,858 --> 00:42:07,028 - Thank you all for having me. 1032 00:42:07,109 --> 00:42:09,019 - Thank you. - Good job. 1033 00:42:09,111 --> 00:42:12,151 - I thought that the whole thing was sharp, 1034 00:42:12,281 --> 00:42:14,321 and guess I was wrong. 1035 00:42:14,450 --> 00:42:17,620 I’m definitely gonna go home, bust out a bunch of knives 1036 00:42:17,703 --> 00:42:20,743 and make sure all those suckers are sharp as hell. 1037 00:42:23,167 --> 00:42:24,467 - Ron, congratulations. 1038 00:42:24,543 --> 00:42:26,293 That makes you the "Forged in Fire" champion, man, 1039 00:42:26,420 --> 00:42:28,290 and you got a check for $10,000. 1040 00:42:28,380 --> 00:42:29,550 Congratulations. 1041 00:42:29,632 --> 00:42:30,962 [applause] 1042 00:42:31,050 --> 00:42:32,550 - I’m--I’m so proud. 1043 00:42:32,635 --> 00:42:35,885 I would encourage anyone to come and try this experience. 1044 00:42:35,971 --> 00:42:38,471 It doesn’t matter whether you’re new to bladesmithing 1045 00:42:38,557 --> 00:42:40,397 or you’re a seasoned veteran. 1046 00:42:40,476 --> 00:42:43,646 If I can do it at 50, you can do it at 25. 1047 00:42:43,729 --> 00:42:47,149 [metal music] 1048 00:42:47,274 --> 00:42:48,614 ♪ ♪