1 00:00:05,172 --> 00:00:09,008 [upbeat rock music] 2 00:00:11,345 --> 00:00:13,070 [adventurous music] 3 00:00:13,088 --> 00:00:14,404 [whip cracks] 4 00:00:14,423 --> 00:00:18,333 ♪ ♪ 5 00:00:18,427 --> 00:00:20,744 [eagle screeches] 6 00:00:20,763 --> 00:00:22,246 [whip cracks] 7 00:00:22,264 --> 00:00:26,083 ♪ ♪ 8 00:00:26,176 --> 00:00:28,919 - I'm gary graham from elkmont, alabama. 9 00:00:28,937 --> 00:00:31,271 12 days after I turned 18, I enlisted in the army, 10 00:00:31,423 --> 00:00:33,181 Flying uh-60 black hawks. 11 00:00:33,275 --> 00:00:34,849 Started making my first blade 12 00:00:34,943 --> 00:00:36,368 After I got home from deployment, 13 00:00:36,595 --> 00:00:39,596 And it continued to grow to a small business now. 14 00:00:39,615 --> 00:00:42,099 ♪ ♪ 15 00:00:42,117 --> 00:00:43,542 - My name's eduardo sol. 16 00:00:43,693 --> 00:00:46,270 I am original from mexico. 17 00:00:46,363 --> 00:00:47,938 I moved to the u.S. ''cause I was 18 00:00:47,956 --> 00:00:49,864 A foreign exchange student during college, 19 00:00:49,884 --> 00:00:51,792 And I met the woman of my dreams. 20 00:00:51,886 --> 00:00:54,720 She got me into blacksmithing, and I got hooked on knives. 21 00:00:54,947 --> 00:00:56,797 ♪ ♪ 22 00:00:56,949 --> 00:01:00,059 - I'm matt aaron. I'm 31 years old. 23 00:01:00,210 --> 00:01:03,136 I use bladesmithing as a way to supplement my hobby 24 00:01:03,289 --> 00:01:05,230 As an armored combat enthusiast. 25 00:01:05,382 --> 00:01:06,881 Being able to create my own weaponry 26 00:01:06,975 --> 00:01:08,642 To a historical spec certainly 27 00:01:08,794 --> 00:01:10,294 Keeps my creative juices flowing, 28 00:01:10,312 --> 00:01:11,403 And it keeps some money in my pocketbook. 29 00:01:11,630 --> 00:01:14,740 ♪ ♪ 30 00:01:14,967 --> 00:01:18,151 - I'm josh langpit. I am from newport, virginia. 31 00:01:18,304 --> 00:01:21,305 I got my start in bladesmithing just before 16. 32 00:01:21,323 --> 00:01:23,473 My dad handed me a fantasy novel that a character 33 00:01:23,567 --> 00:01:24,825 Made a sword using a volcano. 34 00:01:24,977 --> 00:01:27,311 I cried bs at that point. 35 00:01:27,404 --> 00:01:28,903 He asked me to go do some research, 36 00:01:28,997 --> 00:01:30,647 And I found out that it's possible, 37 00:01:30,740 --> 00:01:33,650 And that kinda set things in motion from there. 38 00:01:33,669 --> 00:01:37,245 ♪ ♪ 39 00:01:37,264 --> 00:01:41,325 - Well, bladesmiths, welcome to the forge. 40 00:01:41,343 --> 00:01:43,660 You're here to test yourselves and your bladesmithing skills 41 00:01:43,679 --> 00:01:46,163 Against each other and against our clock. 42 00:01:46,256 --> 00:01:48,165 Now, we've got three intense rounds 43 00:01:48,183 --> 00:01:50,167 Of bladesmithing competition set up for you. 44 00:01:50,185 --> 00:01:51,926 At the end of each one, I'm gonna ask you 45 00:01:51,946 --> 00:01:54,613 To present your work to our panel of expert judges. 46 00:01:54,840 --> 00:01:57,007 Now, bladesmiths, keep in mind they're the ones 47 00:01:57,100 --> 00:01:58,175 Who will be wielding your blades, 48 00:01:58,193 --> 00:02:00,177 Testing them, and making the decisions 49 00:02:00,270 --> 00:02:01,528 As to who's gonna be leaving here 50 00:02:01,680 --> 00:02:03,530 With the title of "forged in fire" champion 51 00:02:03,624 --> 00:02:06,867 And a check for $10,000. 52 00:02:07,019 --> 00:02:08,368 But bladesmiths, today in this competition, 53 00:02:08,462 --> 00:02:09,962 We're gonna be paying tribute 54 00:02:10,189 --> 00:02:12,297 To some badass cowboys from south america: 55 00:02:12,524 --> 00:02:13,857 The gaucho. 56 00:02:13,950 --> 00:02:16,135 Smiths, we want you to build this. 57 00:02:16,362 --> 00:02:20,697 ♪ ♪ 58 00:02:20,716 --> 00:02:22,141 The gaucho knife. 59 00:02:22,368 --> 00:02:25,310 ♪ ♪ 60 00:02:25,537 --> 00:02:27,146 The gaucho knife, also known as the facon, 61 00:02:27,297 --> 00:02:29,148 Got its name from the nomadic cowboys 62 00:02:29,299 --> 00:02:31,799 Of argentina and uruguay, who made it popular. 63 00:02:31,819 --> 00:02:33,986 Tracing its origins back to the 19th century, 64 00:02:34,137 --> 00:02:36,304 This weapon features a sharp single edged blade 65 00:02:36,323 --> 00:02:38,732 Long enough to deliver lethal slashes. 66 00:02:38,884 --> 00:02:40,993 Its short enough to be easily concealed, 67 00:02:41,144 --> 00:02:42,810 Making it the perfect weapon for the gauchos 68 00:02:42,905 --> 00:02:44,312 To use in close quarter combat 69 00:02:44,331 --> 00:02:46,223 Against the spanish soldiers 70 00:02:46,316 --> 00:02:47,815 During the war of independence. 71 00:02:47,835 --> 00:02:50,002 While this knife is known as a fighting knife, 72 00:02:50,229 --> 00:02:52,562 The gauchos still use it for hunting today. 73 00:02:52,656 --> 00:02:54,731 Now, smiths, to build this iconic knife 74 00:02:54,824 --> 00:02:55,899 You're gonna need what is on your anvils 75 00:02:55,918 --> 00:02:58,068 Under that cloth. 76 00:02:58,161 --> 00:03:00,012 So go ahead and remove it for me. 77 00:03:00,239 --> 00:03:02,088 ♪ ♪ 78 00:03:02,183 --> 00:03:05,575 What you see there is a bar of 1084 high carbon steel 79 00:03:05,594 --> 00:03:07,911 And next to it, two bars of mild steel. 80 00:03:08,004 --> 00:03:09,596 We want you to build your gauchos 81 00:03:09,748 --> 00:03:11,339 Using the san mai technique. 82 00:03:11,433 --> 00:03:13,007 That is high carbon sandwiched 83 00:03:13,101 --> 00:03:15,176 In between two bars of mild steel. 84 00:03:15,270 --> 00:03:16,511 Your blade length measured from tip 85 00:03:16,605 --> 00:03:18,012 To where the cutting edge ends 86 00:03:18,032 --> 00:03:20,699 Needs to be between 11 and 13 inches. 87 00:03:20,926 --> 00:03:22,850 And you need to have an integral bolster. 88 00:03:22,945 --> 00:03:24,352 Now, by the end of the first round, 89 00:03:24,446 --> 00:03:25,853 You have to have your blades quenched, 90 00:03:25,948 --> 00:03:27,706 Hardened, and acid etched. 91 00:03:27,933 --> 00:03:30,375 - I've never made a gaucho knife before. 92 00:03:30,527 --> 00:03:32,878 The challenging part is, its all one piece construction, 93 00:03:33,105 --> 00:03:34,880 Having that bolster separated from the blade 94 00:03:35,107 --> 00:03:36,790 And be able to get your tang out of that. 95 00:03:36,942 --> 00:03:38,608 And not to make your bolster too small. 96 00:03:38,702 --> 00:03:40,201 You can't put material back on, 97 00:03:40,221 --> 00:03:42,612 But it's easy to mess it up and make it too small. 98 00:03:42,631 --> 00:03:45,540 So metal management is the key to this competition. 99 00:03:45,634 --> 00:03:46,967 - Now, moving on into round two 100 00:03:47,119 --> 00:03:48,635 For the three of you who join us, 101 00:03:48,787 --> 00:03:50,211 We're gonna ask you add handles to your blades, 102 00:03:50,231 --> 00:03:52,046 Turning them to fully functioning weapons. 103 00:03:52,066 --> 00:03:53,881 You're gonna hand your blades over to our judges, 104 00:03:53,976 --> 00:03:55,141 And they're gonna check for strength and durability 105 00:03:55,236 --> 00:03:57,719 In a wooden gate chop. 106 00:03:57,738 --> 00:03:59,071 And then see how your edges held up 107 00:03:59,222 --> 00:04:02,299 In a gaucho blanket slice. 108 00:04:02,317 --> 00:04:04,225 You guys, you have three hours on the clock. 109 00:04:04,245 --> 00:04:07,471 Good luck and saddle up, 'cause your time starts now. 110 00:04:07,489 --> 00:04:10,898 ♪ ♪ 111 00:04:10,918 --> 00:04:12,642 All right, I love that blade. 112 00:04:12,661 --> 00:04:14,478 - Now, you know what's interesting about the gauchos 113 00:04:14,496 --> 00:04:16,830 Is that it is a subculture in south america 114 00:04:16,924 --> 00:04:19,258 In brazil, argentina, uruguay, 115 00:04:19,485 --> 00:04:21,651 And that is one of the things that defines them. 116 00:04:21,670 --> 00:04:24,654 It is part of their wear. 117 00:04:24,673 --> 00:04:27,248 - San mai, I have made quite a bit of it, 118 00:04:27,342 --> 00:04:30,010 So I am ready to rock and roll. 119 00:04:30,104 --> 00:04:33,346 The 1084, it is clean. 120 00:04:33,440 --> 00:04:37,609 The mild steel is still rough, so that will not forge weld, 121 00:04:37,836 --> 00:04:39,594 So I clean off one side of each 122 00:04:39,688 --> 00:04:41,262 Of the two mild steel bars 123 00:04:41,356 --> 00:04:43,507 So they will mate perfectly. 124 00:04:43,600 --> 00:04:45,692 - You don't need to clean all sides of everything. 125 00:04:45,844 --> 00:04:46,785 - So just a real quick pass. 126 00:04:46,936 --> 00:04:48,361 - Yeah. - Clean it up. 127 00:04:48,455 --> 00:04:50,347 - That's really all it takes. 128 00:04:50,440 --> 00:04:52,457 - I stack my steel like a sandwich-- 129 00:04:52,684 --> 00:04:56,295 1084 is the meat, the mild steel is the bread. 130 00:04:56,522 --> 00:04:58,613 The good 1084 steel is your cutting edge. 131 00:04:58,632 --> 00:05:00,799 That'll hold. 132 00:05:00,950 --> 00:05:03,302 The mild steel is nice and soft and ready to absorb any blows. 133 00:05:03,453 --> 00:05:04,786 I feel great. 134 00:05:04,880 --> 00:05:06,530 I think I set myself up for success. 135 00:05:06,548 --> 00:05:08,956 ♪ ♪ 136 00:05:09,051 --> 00:05:11,643 - San mai is a process I use quite a bit in the forge, 137 00:05:11,870 --> 00:05:13,887 So I really lucked out with this challenge. 138 00:05:13,981 --> 00:05:15,480 The first thing I need to do 139 00:05:15,707 --> 00:05:18,150 Is get the two pieces mild steel cleaned up. 140 00:05:18,377 --> 00:05:21,302 I don't wanna take any chance of a delam during my weld. 141 00:05:21,322 --> 00:05:23,137 - Gary went straight back to the mig welder, 142 00:05:23,157 --> 00:05:25,549 And he's putting it together. 143 00:05:25,567 --> 00:05:27,826 - I think the crossover between flying helicopters 144 00:05:28,053 --> 00:05:30,904 And bladesmithing is the attention to detail. 145 00:05:30,998 --> 00:05:33,314 You got to be mission oriented and know the time on target 146 00:05:33,334 --> 00:05:34,724 That you've got to be there, 147 00:05:34,818 --> 00:05:36,393 And it's the same with this competition. 148 00:05:36,411 --> 00:05:38,228 You got to break down on legs of what you've got to do 149 00:05:38,246 --> 00:05:39,729 To get to the next step, 150 00:05:39,748 --> 00:05:41,006 And you got to be on time in three hours. 151 00:05:41,233 --> 00:05:43,675 ♪ ♪ 152 00:05:43,902 --> 00:05:45,677 - I am familiar with the san mai technique, 153 00:05:45,904 --> 00:05:48,496 But I have not made the gaucho knife. 154 00:05:48,590 --> 00:05:49,348 I've seen them. 155 00:05:49,575 --> 00:05:51,074 Welding! 156 00:05:51,167 --> 00:05:53,018 - Having done "forged in fire" in latin america, 157 00:05:53,245 --> 00:05:55,745 I actually got to be exposed to the gaucho knife 158 00:05:55,839 --> 00:05:58,005 Because we had a contestant that was a gaucho, 159 00:05:58,100 --> 00:06:00,025 And he made a gaucho knife. 160 00:06:00,252 --> 00:06:02,677 - It's time to get ready to set the weld. 161 00:06:02,771 --> 00:06:04,270 My biggest concern is making sure 162 00:06:04,423 --> 00:06:06,180 My weld set off the get go. 163 00:06:06,274 --> 00:06:08,015 With the san mai construction, 164 00:06:08,110 --> 00:06:11,945 You don't have that many layers to back up any delaminations. 165 00:06:12,039 --> 00:06:15,098 You have two welds, and those two welds have to hold. 166 00:06:15,117 --> 00:06:16,875 - You start hammering on that cold, 167 00:06:17,026 --> 00:06:20,712 Your chances of popping those two welds really goes up. 168 00:06:20,864 --> 00:06:22,439 - Billet appears to be right at about 169 00:06:22,457 --> 00:06:24,365 Where I think welding temperature is at, 170 00:06:24,385 --> 00:06:27,627 So I'm going to set my welds nice and light. 171 00:06:27,721 --> 00:06:31,297 Just nice, even taps to get everything stuck together. 172 00:06:31,450 --> 00:06:32,632 My welds are looking pretty good. 173 00:06:32,784 --> 00:06:34,559 Right back into the forge to keep it hot. 174 00:06:34,711 --> 00:06:36,970 And now we wait. 175 00:06:37,122 --> 00:06:38,955 - I think the most difficult aspect 176 00:06:39,048 --> 00:06:42,901 Of the entire competition is that time constraint. 177 00:06:43,128 --> 00:06:47,130 Also, I don't have much practice in a gas forge. 178 00:06:47,149 --> 00:06:51,058 I exclusively use coal. 179 00:06:51,153 --> 00:06:52,986 - Josh is setting his first weld with a hand hammer. 180 00:06:53,138 --> 00:06:54,471 - Yeah. 181 00:06:54,564 --> 00:06:55,972 - There's a little bit more propensity 182 00:06:56,065 --> 00:06:58,491 Of weld flaws if you do that. 183 00:06:58,585 --> 00:07:01,161 - Bladesmiths, you only have two hours left 184 00:07:01,255 --> 00:07:02,812 To finish your gaucho. 185 00:07:02,831 --> 00:07:04,923 ♪ ♪ 186 00:07:05,074 --> 00:07:06,425 - Things are looking good at this point. 187 00:07:06,576 --> 00:07:08,743 I go to the press, and I do some nice gentle presses 188 00:07:08,837 --> 00:07:09,986 To get it welded together. 189 00:07:10,005 --> 00:07:11,430 ♪ ♪ 190 00:07:11,581 --> 00:07:13,840 - And when I see that first weld, I wanna see 191 00:07:13,934 --> 00:07:16,676 That billet the same color as the inside of the forge. 192 00:07:16,770 --> 00:07:18,270 - Well, he wasn't quite there. 193 00:07:18,497 --> 00:07:20,513 - He's pressing everything down pretty cold. 194 00:07:20,666 --> 00:07:23,166 All you're doing is building stress in the steel. 195 00:07:23,185 --> 00:07:25,092 - I look at my layers, 196 00:07:25,112 --> 00:07:26,928 And I don't see any shadows between those pieces, 197 00:07:27,022 --> 00:07:28,780 So I'm confident my forge weld was stuck. 198 00:07:29,007 --> 00:07:32,175 ♪ ♪ 199 00:07:32,194 --> 00:07:35,011 - What makes a gaucho knife unique is that integral bolster 200 00:07:35,030 --> 00:07:36,270 At the back of the blade. 201 00:07:36,364 --> 00:07:38,957 It acts as both part of the handle 202 00:07:39,184 --> 00:07:41,868 And a guard as well. 203 00:07:42,020 --> 00:07:45,371 - I would definitely start out by isolating that bolster. 204 00:07:45,466 --> 00:07:48,633 Whether I form it immediately or not, I'd isolate it. 205 00:07:48,860 --> 00:07:52,304 - I am isolating my bolster from the rest of the blade. 206 00:07:52,531 --> 00:07:55,456 I use the corner of the anvil to kind of mark it 207 00:07:55,550 --> 00:07:58,368 And make a nice little step down. 208 00:07:58,386 --> 00:08:00,479 Everything looks good to my eye, 209 00:08:00,706 --> 00:08:03,148 And I just need to shape the rest of the blade. 210 00:08:03,375 --> 00:08:05,725 ♪ ♪ 211 00:08:05,877 --> 00:08:07,393 - This challenge was made for me. 212 00:08:07,546 --> 00:08:09,713 I have made these knives before, 213 00:08:09,731 --> 00:08:14,326 I have actually met gauchos, and I know I can do this. 214 00:08:14,553 --> 00:08:16,219 The trick about forging an integral bolster is, 215 00:08:16,238 --> 00:08:18,221 It's all the same metal. 216 00:08:18,240 --> 00:08:21,407 If I'm not careful, it will be lopsided 217 00:08:21,560 --> 00:08:23,226 And can get me sent home. 218 00:08:23,319 --> 00:08:25,395 - On first appearances, the gaucho knife 219 00:08:25,488 --> 00:08:27,897 Seems relatively simple, but when you get into it, 220 00:08:27,991 --> 00:08:30,324 Especially around the bolster and the heel area 221 00:08:30,418 --> 00:08:32,418 Of this knife, you really got to know 222 00:08:32,571 --> 00:08:34,921 How to move the middle where you want it. 223 00:08:35,073 --> 00:08:39,184 - I get a rough blade profile, and I am ecstatic. 224 00:08:39,411 --> 00:08:42,837 ♪ ♪ 225 00:08:42,856 --> 00:08:44,597 - As I start to shape this blade, 226 00:08:44,691 --> 00:08:48,026 I'm really concerned about that bolster in particular. 227 00:08:48,253 --> 00:08:51,771 So I wanna isolate that area so that I make sure 228 00:08:51,865 --> 00:08:55,200 That I leave enough material there that I can get that 229 00:08:55,351 --> 00:08:58,611 And the length I need to make a through tang. 230 00:08:58,764 --> 00:09:00,688 - It seems that josh is only 231 00:09:00,782 --> 00:09:03,116 Using his hammer in this process. 232 00:09:03,210 --> 00:09:05,618 - You know, with a timed competition there comes a point 233 00:09:05,771 --> 00:09:10,106 You're just using too much time and moving too little metal. 234 00:09:10,125 --> 00:09:13,126 - I'm used to hand hammer and hand tooling. 235 00:09:13,220 --> 00:09:16,370 While I really do want to represent that skill set, 236 00:09:16,390 --> 00:09:18,390 I don't have that luxury here. 237 00:09:18,541 --> 00:09:20,950 I'm starting to feel the pressure of the clock, 238 00:09:20,969 --> 00:09:23,728 And as I'm working that bolster by hand, I realize 239 00:09:23,880 --> 00:09:26,139 That if I use a press, I can save time 240 00:09:26,291 --> 00:09:29,050 And a whole lot of effort. [laughs] 241 00:09:29,069 --> 00:09:31,961 Looks like it's coming together just fine. 242 00:09:31,980 --> 00:09:34,739 - Bladesmiths, you are down to one hour. 243 00:09:34,966 --> 00:09:37,242 ♪ ♪ 244 00:09:37,469 --> 00:09:39,986 - I was on forging, the tang's gone big blue, 245 00:09:40,138 --> 00:09:41,304 I look and I see the end of my tang 246 00:09:41,323 --> 00:09:43,156 Starting to mushroom out. 247 00:09:43,250 --> 00:09:44,641 Damn it. 248 00:09:44,734 --> 00:09:46,643 Obvious cold shuts on the end of it. 249 00:09:46,661 --> 00:09:48,645 If I continue without getting rid of it, 250 00:09:48,663 --> 00:09:51,423 It'll progress all the way up into delam end on my bolster, 251 00:09:51,650 --> 00:09:54,092 And I would have to start out with a new billet. 252 00:09:54,243 --> 00:09:57,095 - So working his billet cold has definitely bit gary. 253 00:09:57,246 --> 00:09:59,413 - I decided to tack weld that up 254 00:09:59,433 --> 00:10:00,824 To eliminate that problem so I wouldn't have 255 00:10:00,842 --> 00:10:02,767 Any future problem with the end of my tang. 256 00:10:02,994 --> 00:10:04,677 Time's ticking, and I need to forge out my blade. 257 00:10:04,771 --> 00:10:08,089 I'm feeling worried. 258 00:10:08,108 --> 00:10:11,184 - The san mai has a tendency to warp in the quench, 259 00:10:11,278 --> 00:10:14,929 Especially if you have heated one side more than the other 260 00:10:14,948 --> 00:10:17,523 Or you have thinner mild on one side than the other. 261 00:10:17,676 --> 00:10:19,451 So to mitigate this, I wanna quench thick 262 00:10:19,678 --> 00:10:21,861 And then grind thin. 263 00:10:22,013 --> 00:10:23,696 - Look at matt's blade right now. 264 00:10:23,790 --> 00:10:27,108 That is way above where it needs to be to be quenched. 265 00:10:27,202 --> 00:10:28,609 - Yeah, with the wrong temperatures, 266 00:10:28,703 --> 00:10:30,186 We've seen them split apart. 267 00:10:30,205 --> 00:10:32,689 ♪ ♪ 268 00:10:32,707 --> 00:10:34,374 - So matt's in the oil. 269 00:10:34,468 --> 00:10:36,359 - Everything's straight. 270 00:10:36,378 --> 00:10:38,027 I have a lot of weight on this blade, 271 00:10:38,121 --> 00:10:40,454 So I let it cool down as much as I can. 272 00:10:40,474 --> 00:10:42,307 I'm gonna hog a lot of metal off. 273 00:10:42,534 --> 00:10:45,218 ♪ ♪ 274 00:10:45,312 --> 00:10:48,313 - Everything is rough shaped, the blade is ready to rock. 275 00:10:48,540 --> 00:10:50,148 ♪ ♪ 276 00:10:50,375 --> 00:10:53,226 - Eduardo just quenched at the right temperature. 277 00:10:53,378 --> 00:10:54,727 - The hardest part is over. 278 00:10:54,821 --> 00:10:55,879 [laughs] 279 00:10:55,897 --> 00:10:57,322 My blade is hard. 280 00:10:57,549 --> 00:11:00,158 Now I just need to pretty to this bad boy up. 281 00:11:00,385 --> 00:11:02,494 I hit the grinder, and I'm just digging into it. 282 00:11:02,721 --> 00:11:04,145 ♪ ♪ 283 00:11:04,239 --> 00:11:07,390 I stop to check parameters. 284 00:11:07,409 --> 00:11:08,083 - Something's going on. 285 00:11:09,744 --> 00:11:13,062 I grind my blade under 11 inches. 286 00:11:13,156 --> 00:11:14,898 I no longer meet parameters. - Uh-oh. 287 00:11:14,991 --> 00:11:16,508 If he's short, then he absolutely 288 00:11:16,659 --> 00:11:18,492 Has to get that length in order to move forward. 289 00:11:18,512 --> 00:11:20,327 - Oh, [bleep]. 290 00:11:20,422 --> 00:11:22,405 I can't figure a way out without putting this back 291 00:11:22,498 --> 00:11:24,757 In the fire to stretch my steel. 292 00:11:24,910 --> 00:11:29,170 My blade is 90% done, and I have to go back in the fire. 293 00:11:29,264 --> 00:11:31,247 I'm worried that I don't have the time 294 00:11:31,266 --> 00:11:32,357 To get this blade done. 295 00:11:32,584 --> 00:11:32,857 [bleep] 296 00:11:37,589 --> 00:11:38,863 - I have to get back in the fire. 297 00:11:39,015 --> 00:11:41,032 - He has to get within parameters. 298 00:11:41,184 --> 00:11:44,944 - I'm very overwhelmed, but I'm up against the clock, 299 00:11:45,096 --> 00:11:47,947 So I just gotta get this blade ready to requench, 300 00:11:48,041 --> 00:11:51,209 Making sure I have way more steel than I need. 301 00:11:51,360 --> 00:11:53,937 - Bladesmiths, you have 30 minutes. 302 00:11:53,955 --> 00:11:56,530 ♪ ♪ 303 00:11:56,550 --> 00:11:58,883 - Josh, if you look at the profile he's got, 304 00:11:59,035 --> 00:12:01,127 The blade profile is pretty spot on. 305 00:12:01,279 --> 00:12:02,445 ♪ ♪ 306 00:12:02,538 --> 00:12:04,781 - Jeez, that's hot. - Holy-- 307 00:12:04,874 --> 00:12:06,558 - Everything looks like its good, 308 00:12:06,709 --> 00:12:09,376 But it does have a little bit of a snake to it. 309 00:12:09,396 --> 00:12:12,956 But I really feel like it's still within grindability. 310 00:12:12,974 --> 00:12:14,640 Hopefully, I'll be able to get it done. 311 00:12:14,793 --> 00:12:16,884 ♪ ♪ 312 00:12:16,978 --> 00:12:18,478 - I'm ready for quenching. 313 00:12:18,630 --> 00:12:20,146 ♪ ♪ 314 00:12:20,298 --> 00:12:21,981 - Eduardo's in the oil, 315 00:12:22,075 --> 00:12:25,392 Extremely hot, we might see some splitting going on. 316 00:12:25,412 --> 00:12:27,078 - It comes out straight, 317 00:12:27,230 --> 00:12:29,155 And I'm well within my parameters. 318 00:12:29,249 --> 00:12:31,975 I am so relieved. 319 00:12:31,993 --> 00:12:35,161 But I still got a lot of things to do and not much time left. 320 00:12:35,313 --> 00:12:37,814 Whew. 321 00:12:37,832 --> 00:12:39,832 - I'm on the grinder and getting towards the end, 322 00:12:39,985 --> 00:12:41,501 So it's time to quench. 323 00:12:41,653 --> 00:12:42,743 ♪ ♪ 324 00:12:42,763 --> 00:12:43,911 - There we go. 325 00:12:44,005 --> 00:12:45,263 - Nice color. - Nice. 326 00:12:45,414 --> 00:12:47,824 - All right, four quenched blades. 327 00:12:47,842 --> 00:12:49,750 - I've got one little warp, so I go over 328 00:12:49,770 --> 00:12:51,770 And correct that on the anvil. 329 00:12:51,921 --> 00:12:54,105 I put a little pressure on it, straighten it up. 330 00:12:54,257 --> 00:12:56,165 I still had enough meat left on it to straighten it out 331 00:12:56,184 --> 00:12:58,835 On the final grind before turning it to the judges. 332 00:12:58,853 --> 00:13:01,187 ♪ ♪ 333 00:13:01,339 --> 00:13:03,172 - As I'm grinding the blade for a second time... 334 00:13:03,191 --> 00:13:04,857 Oh, [bleep]. 335 00:13:04,951 --> 00:13:07,026 I feel a pop. 336 00:13:07,178 --> 00:13:10,288 There is a seam from the top of the blade 337 00:13:10,439 --> 00:13:12,031 All the way to the bottom. 338 00:13:12,183 --> 00:13:13,440 [sighs] 339 00:13:13,460 --> 00:13:16,035 I have a catastrophic failure. 340 00:13:16,187 --> 00:13:18,204 - We've probably seen dozens of times when we ask a smith 341 00:13:18,356 --> 00:13:19,780 To do the san mai technique, 342 00:13:19,800 --> 00:13:21,115 The problems really start to arise 343 00:13:21,209 --> 00:13:23,209 When they hit the grinder. 344 00:13:23,303 --> 00:13:27,788 - I have to basically re-forge weld my san mai. 345 00:13:27,808 --> 00:13:30,033 I'm thinking I'm gonna get sent home. 346 00:13:30,051 --> 00:13:32,051 I don't have the time to start over, 347 00:13:32,203 --> 00:13:34,312 But I am not giving up. 348 00:13:34,463 --> 00:13:36,539 - It's not a good sign for eduardo, man. 349 00:13:36,632 --> 00:13:39,300 He's in for his third quench now. 350 00:13:39,319 --> 00:13:42,545 - With a third quench, the grains are going to expand, 351 00:13:42,564 --> 00:13:44,471 My blade has become brittle. 352 00:13:44,491 --> 00:13:47,975 I am terrified that this is gonna just shatter like glass, 353 00:13:48,069 --> 00:13:49,402 But I don't have a choice. 354 00:13:49,554 --> 00:13:50,662 ♪ ♪ 355 00:13:50,813 --> 00:13:53,164 I have to get this blade to a grinder 356 00:13:53,391 --> 00:13:56,668 And finish this blade and meet parameters. 357 00:13:56,819 --> 00:14:00,672 - Bladesmiths, you have 15 minutes. 358 00:14:00,899 --> 00:14:02,841 - In order to finish off this blade, I need to pull 359 00:14:02,992 --> 00:14:07,086 The mild steel back and reveal the core metal. 360 00:14:07,238 --> 00:14:10,515 As I'm grinding away, there's a frickin' crack 361 00:14:10,666 --> 00:14:13,259 Almost the whole length of the spine. 362 00:14:13,411 --> 00:14:15,687 - Oh, what is going on here? 363 00:14:15,914 --> 00:14:18,081 - Given the time constraints, I'm gonna go over, 364 00:14:18,099 --> 00:14:21,084 Put a bead of weld right down the spine of this. 365 00:14:21,102 --> 00:14:23,269 That's gonna at least give me a point of contact 366 00:14:23,363 --> 00:14:28,107 So that I don't pop loose anything else in the billet. 367 00:14:28,259 --> 00:14:30,201 - When you have a delamination on the blade, 368 00:14:30,353 --> 00:14:32,111 One of the things you really have to be smart about 369 00:14:32,263 --> 00:14:34,614 Is cleaning it out, or what you're gonna have 370 00:14:34,708 --> 00:14:37,450 Is rust forming down at the base of that crack. 371 00:14:37,544 --> 00:14:40,044 So that mild steel weld at the top is gonna keep it 372 00:14:40,196 --> 00:14:41,771 From cracking there. 373 00:14:41,789 --> 00:14:44,531 That crack might open from the edge now. 374 00:14:44,551 --> 00:14:48,628 - I'm fairly comfortable that I've alleviated this crack, 375 00:14:48,722 --> 00:14:53,116 But right on the edge, there's this travelling crack. 376 00:14:53,209 --> 00:14:54,450 I'm starting to run out of time, 377 00:14:54,469 --> 00:14:56,802 So I can't redo this again. 378 00:14:56,897 --> 00:15:00,381 I think I'm pretty okay in just grinding this back. 379 00:15:00,400 --> 00:15:03,142 Hopefully it doesn't come back and bite me in the butt. 380 00:15:03,294 --> 00:15:05,628 ♪ ♪ 381 00:15:05,647 --> 00:15:07,480 - I get my blade to a shape that I like. 382 00:15:07,632 --> 00:15:10,241 So I put it in the etch so that I can see 383 00:15:10,468 --> 00:15:12,076 That I've exposed high carbon material 384 00:15:12,228 --> 00:15:14,245 All the way down my blade. 385 00:15:14,397 --> 00:15:17,490 I've got high carbon steel all the way down the middle. 386 00:15:17,642 --> 00:15:20,159 Everything looks right until I flip it over. 387 00:15:20,311 --> 00:15:23,479 I have a crack right down the center of my blade. 388 00:15:23,498 --> 00:15:25,089 - This could be disastrous. 389 00:15:25,241 --> 00:15:27,592 - We talk about the problems that develop with san mai, 390 00:15:27,743 --> 00:15:29,652 Some of the splitting that we see, 391 00:15:29,745 --> 00:15:31,412 Most of that comes from the fact 392 00:15:31,431 --> 00:15:34,006 That the smiths are quenching these blades 393 00:15:34,159 --> 00:15:36,342 Hundreds of degrees hotter than they should be quenched. 394 00:15:36,494 --> 00:15:37,769 - Yep. 395 00:15:37,920 --> 00:15:39,437 - It's looking deep, and I don't know 396 00:15:39,588 --> 00:15:42,607 If I have enough material to grind this thing out. 397 00:15:42,834 --> 00:15:45,777 If can't get it out, that could send me home. 398 00:15:45,928 --> 00:15:48,854 So I run over to the mig station to keep the crack 399 00:15:49,007 --> 00:15:51,174 From spreading any further. 400 00:15:51,192 --> 00:15:54,768 I think I've managed to stop the crack from spreading. 401 00:15:54,788 --> 00:15:56,437 It's back to the grinder again 402 00:15:56,456 --> 00:15:59,940 To get as much of that blobiness out of it as I can. 403 00:15:59,960 --> 00:16:05,129 - Five, four, three, two, one. 404 00:16:05,281 --> 00:16:08,708 Bladesmiths, the first round of this competition is over. 405 00:16:08,860 --> 00:16:12,211 - I am elated that I am turning in a blade. 406 00:16:12,363 --> 00:16:15,198 But with a third quench, the grain of this blade 407 00:16:15,216 --> 00:16:16,790 Has expanded and contracted. 408 00:16:16,810 --> 00:16:19,885 I am very concerned that my blade 409 00:16:20,038 --> 00:16:23,147 Is gonna be a lot rougher than my competitors. 410 00:16:23,374 --> 00:16:24,965 - Bladesmiths, in the first three hours 411 00:16:24,985 --> 00:16:27,134 Of this competition, you took three pieces of metal 412 00:16:27,228 --> 00:16:30,137 And turned them into your own renditions of the gaucho knife. 413 00:16:30,156 --> 00:16:32,639 The time has come for your first critique, 414 00:16:32,659 --> 00:16:34,233 And unfortunately, an elimination. 415 00:16:34,385 --> 00:16:35,660 Gary, you're up first. You ready? 416 00:16:35,887 --> 00:16:37,161 - I'm ready. - Please present your work. 417 00:16:39,557 --> 00:16:40,981 - All right, gary, you've got a nice form 418 00:16:41,001 --> 00:16:42,500 Of the gaucho knife. 419 00:16:42,727 --> 00:16:45,152 And you were very careful with your temperatures, 420 00:16:45,171 --> 00:16:48,397 Especially when you quenched, so the steel looks pristine. 421 00:16:48,416 --> 00:16:51,751 The bolster looks great. Overall, clean work. Good job. 422 00:16:51,903 --> 00:16:53,252 - Thank you. - Eduardo, how are you feeling? 423 00:16:53,346 --> 00:16:54,679 - Pretty good. 424 00:16:54,906 --> 00:16:56,572 - All right, please present your work. 425 00:16:56,591 --> 00:16:58,424 ♪ ♪ 426 00:16:58,576 --> 00:17:00,593 - All right, eduardo, it's pretty much spot on 427 00:17:00,745 --> 00:17:02,186 As far as the profile goes. 428 00:17:02,338 --> 00:17:03,763 If you move forward, 429 00:17:03,857 --> 00:17:07,933 There's the slightest crack on the steel here. 430 00:17:08,086 --> 00:17:10,194 I have a feeling it's very close to the surface 431 00:17:10,346 --> 00:17:12,864 And not very deep, very slight, but would be a good idea 432 00:17:13,015 --> 00:17:16,016 To address, but it's looking good. 433 00:17:16,110 --> 00:17:17,201 - Matt, how are you doing? 434 00:17:17,428 --> 00:17:18,594 - Pretty good, all things considered. 435 00:17:18,613 --> 00:17:20,038 - All right, please present your work. 436 00:17:21,449 --> 00:17:22,874 ♪ ♪ 437 00:17:23,101 --> 00:17:24,283 - All right, matt, first thing I feel 438 00:17:24,435 --> 00:17:25,692 When I pick up your knife is that it's got 439 00:17:25,712 --> 00:17:27,436 A lot of mass left, a lot of grinding ahead of you 440 00:17:27,530 --> 00:17:28,788 If you move forward from here. 441 00:17:28,940 --> 00:17:30,790 Your forge welds look good. 442 00:17:30,942 --> 00:17:32,884 But the one thing, though, that is alarming to me 443 00:17:33,035 --> 00:17:35,386 Is that there is a crack along the edge of your blade 444 00:17:35,538 --> 00:17:36,554 Deep enough and wide enough for me 445 00:17:36,705 --> 00:17:38,798 To get my fingernail deep in there. 446 00:17:38,892 --> 00:17:41,951 That's in a very critical spot, and it's quite deep, 447 00:17:42,044 --> 00:17:44,228 And it's right in the center. 448 00:17:44,380 --> 00:17:45,379 - Josh, last but not least, you ready? 449 00:17:45,398 --> 00:17:48,124 - Indeed. - Please present your work 450 00:17:48,142 --> 00:17:49,901 ♪ ♪ 451 00:17:50,128 --> 00:17:51,811 - All right, josh, after you quenched, 452 00:17:51,905 --> 00:17:54,146 You were able to identify a crack on your spine. 453 00:17:54,299 --> 00:17:55,556 You welded that in. 454 00:17:55,575 --> 00:17:57,408 In doing so, you opened up some cracks 455 00:17:57,635 --> 00:18:00,136 On the edge where it's really critical. 456 00:18:00,154 --> 00:18:02,655 The good thing is, you were able to grind out most, 457 00:18:02,807 --> 00:18:04,231 And you have a strong edge here. 458 00:18:04,250 --> 00:18:05,917 Should you move forward, 459 00:18:06,068 --> 00:18:07,810 There's a lot of grinding right here 460 00:18:07,903 --> 00:18:09,754 To get it even, but good job. 461 00:18:12,166 --> 00:18:13,666 - Well, guys, in the first round of competition, 462 00:18:13,760 --> 00:18:15,668 You guys all turned in blades that met parameters, 463 00:18:15,820 --> 00:18:16,928 So you all have something to be proud of, 464 00:18:17,079 --> 00:18:18,745 But the judges had a decision to make, 465 00:18:18,765 --> 00:18:20,264 And the bladesmith that's not 466 00:18:20,491 --> 00:18:22,007 Gonna be moving forward in this competition is... 467 00:18:22,160 --> 00:18:23,509 ♪ ♪ 468 00:18:23,661 --> 00:18:24,936 Matt. 469 00:18:25,087 --> 00:18:26,437 Unfortunately, you didn't make the cut. 470 00:18:26,589 --> 00:18:27,921 Dave baker is gonna tell you why. 471 00:18:27,941 --> 00:18:29,332 - Matt, it really comes down to that crack 472 00:18:29,350 --> 00:18:31,258 Being dead center on your edge. 473 00:18:31,277 --> 00:18:33,853 It's splitting the actual steel right down the middle. 474 00:18:34,005 --> 00:18:35,113 There's really not an easy fix for that, 475 00:18:35,340 --> 00:18:36,188 And that's why we're letting you go. 476 00:18:36,282 --> 00:18:38,023 - I understand. 477 00:18:38,176 --> 00:18:40,267 - Well, matt, you're very clearly a talented smith. 478 00:18:40,286 --> 00:18:42,120 But unfortunately, your time in this competition has ended. 479 00:18:42,271 --> 00:18:44,104 I'm gonna have to ask you to please surrender your work 480 00:18:44,124 --> 00:18:46,624 And step off the forge floor. 481 00:18:46,851 --> 00:18:50,186 - I did not see that crack until I etched again. 482 00:18:50,204 --> 00:18:51,687 - Really good-looking profile, matt. 483 00:18:51,706 --> 00:18:53,614 - Thanks, guys. 484 00:18:53,633 --> 00:18:55,191 So there's really very little I could have done about it. 485 00:18:55,209 --> 00:18:57,026 But the experience here was a blast. 486 00:18:57,044 --> 00:18:59,637 ♪ ♪ 487 00:18:59,788 --> 00:19:00,954 - All right, bladesmiths, congratulations. 488 00:19:01,048 --> 00:19:02,640 The three of you are joining us 489 00:19:02,791 --> 00:19:05,292 In the second round of the gaucho knife competition. 490 00:19:05,311 --> 00:19:07,536 Now in this round, we ask you add handles to your blades, 491 00:19:07,555 --> 00:19:09,480 Turning them to fully functioning gaucho knives. 492 00:19:09,707 --> 00:19:11,374 But first, you got to fix any of the issues 493 00:19:11,467 --> 00:19:13,467 That the judges brought forward. 494 00:19:13,561 --> 00:19:16,061 The good news about this round, guys, is the pantry is open. 495 00:19:16,156 --> 00:19:18,214 Bad news is, the only thing you can use from there 496 00:19:18,307 --> 00:19:20,158 Has to be sourced from an animal-- 497 00:19:20,309 --> 00:19:24,904 Bones, antlers, horns, or leather. 498 00:19:25,056 --> 00:19:26,497 When this round is complete, we're gonna test your blades 499 00:19:26,649 --> 00:19:29,483 For strength and durability in a wooden gate chop. 500 00:19:29,502 --> 00:19:30,835 Then they're gonna check your edge retention 501 00:19:30,986 --> 00:19:33,838 In a gaucho blanket slice. 502 00:19:34,065 --> 00:19:35,155 We've got two hours on the clock for you, 503 00:19:35,175 --> 00:19:36,081 So good luck. 504 00:19:36,176 --> 00:19:39,418 That time starts now. 505 00:19:39,570 --> 00:19:41,904 If you guys were in this competition right now, 506 00:19:41,923 --> 00:19:44,331 What handle material would you be seeking out? 507 00:19:44,350 --> 00:19:45,850 - There are a number of antlers over there 508 00:19:46,001 --> 00:19:47,910 That are perfectly usable. 509 00:19:48,003 --> 00:19:50,188 And the nice thing about antler is, 510 00:19:50,339 --> 00:19:52,264 Is you need to drill a hole through it, 511 00:19:52,417 --> 00:19:54,583 Taper the ends a little bit, and you're done. 512 00:19:54,602 --> 00:19:57,420 I mean, that's all that is right in the example. 513 00:19:57,513 --> 00:19:58,845 - There's some warthog intestine. 514 00:19:58,940 --> 00:20:00,198 - I've never used that stuff, 515 00:20:00,349 --> 00:20:03,426 So I'm trying to stick to what I know. 516 00:20:03,444 --> 00:20:04,777 - All right, so it seems gary's 517 00:20:04,929 --> 00:20:06,537 In a pretty good spot right now. 518 00:20:06,764 --> 00:20:09,540 - Oh, yeah. - Oh, yeah, by far the best. 519 00:20:09,692 --> 00:20:11,542 - I feel pretty confident to be able to take my time 520 00:20:11,694 --> 00:20:13,619 And pace myself through round two. 521 00:20:13,771 --> 00:20:14,937 I like that. 522 00:20:15,030 --> 00:20:16,789 I select a piece of water buffalo. 523 00:20:16,941 --> 00:20:18,607 ♪ ♪ 524 00:20:18,626 --> 00:20:19,775 I knew that it would be easy to grind down 525 00:20:19,868 --> 00:20:21,702 And get to the shape I was looking for. 526 00:20:21,721 --> 00:20:23,295 - A water buffalo horn is really tough. 527 00:20:23,448 --> 00:20:24,889 You can throw it on the ground, 528 00:20:25,116 --> 00:20:27,207 It's bomb proof, it's waterproof, good stuff. 529 00:20:27,301 --> 00:20:28,559 - I drill into my horn, 530 00:20:28,786 --> 00:20:30,228 Fit it up with my tang, I'm feeling good. 531 00:20:30,379 --> 00:20:31,729 That's pretty nice. 532 00:20:31,880 --> 00:20:33,046 So now I can get it into the glue 533 00:20:33,140 --> 00:20:34,457 Up on the handle. 534 00:20:34,475 --> 00:20:35,733 ♪ ♪ 535 00:20:35,884 --> 00:20:37,401 - The judges told me 536 00:20:37,628 --> 00:20:40,145 That there was a slight crack on the blade. 537 00:20:40,298 --> 00:20:43,632 So I've got to really make sure I get that crack ground out. 538 00:20:43,651 --> 00:20:47,245 - Something josh could do that would help him a lot, 539 00:20:47,396 --> 00:20:49,822 Is do a hollow grind on that blade. 540 00:20:49,916 --> 00:20:51,657 Then he'd be pushing that crack higher and higher, 541 00:20:51,809 --> 00:20:53,642 Come back, reweld that crack, 542 00:20:53,661 --> 00:20:56,479 Then marry that all in with that faded hollow grind. 543 00:20:56,497 --> 00:20:59,239 - I did the best I could to grind the crack out, 544 00:20:59,333 --> 00:21:00,983 But it's still there. 545 00:21:01,002 --> 00:21:03,928 I can feel the time running down on me. 546 00:21:04,155 --> 00:21:07,490 I really have to move on to the handle. 547 00:21:07,508 --> 00:21:09,934 - I'm very relieved I've made it this far. 548 00:21:10,085 --> 00:21:12,252 Top of the list. 549 00:21:12,272 --> 00:21:15,606 I've got to address the minor crack on my cutting edge. 550 00:21:15,758 --> 00:21:18,167 - Eduardo, as he grinds, that crack could get worse, 551 00:21:18,185 --> 00:21:19,277 Or if it's a surface crack, 552 00:21:19,428 --> 00:21:21,670 As he grinds, that could go away. 553 00:21:21,689 --> 00:21:23,614 - Perfect. 554 00:21:23,766 --> 00:21:26,600 I am so relieved everything has held up. 555 00:21:26,619 --> 00:21:29,695 There are no cracks, and I have a great, solid blade. 556 00:21:29,847 --> 00:21:33,182 [laughs] 557 00:21:33,200 --> 00:21:34,625 - I've got my handle on my tang, and I know 558 00:21:34,852 --> 00:21:35,793 I've got to add a mechanical bond 559 00:21:36,020 --> 00:21:38,521 To hold that butt cap onto the handle. 560 00:21:38,614 --> 00:21:39,630 - He's gonna peen the tang over. 561 00:21:39,782 --> 00:21:41,782 Yeah, there you go. 562 00:21:41,876 --> 00:21:44,860 - I'm really concerned about ruining my epoxy and my handle 563 00:21:44,879 --> 00:21:47,029 By getting the tang too hot. 564 00:21:47,122 --> 00:21:50,199 If I destroy my epoxy bond, 565 00:21:50,217 --> 00:21:52,201 During impact, that butt cap can come off, 566 00:21:52,219 --> 00:21:55,220 It is a critical failure, it could send me home. 567 00:21:55,315 --> 00:21:57,297 I'm hoping that it's strong enough bond to hold 568 00:21:57,317 --> 00:21:59,542 That butt cap onto the handle. 569 00:21:59,560 --> 00:22:01,544 All right. 570 00:22:01,637 --> 00:22:02,653 - All right, guys, you're halfway 571 00:22:02,805 --> 00:22:04,063 Through this handle round. 572 00:22:04,215 --> 00:22:06,382 You have one hour left. 573 00:22:06,400 --> 00:22:10,719 - I am not a fan of using animal products 574 00:22:10,813 --> 00:22:13,389 Because it stinks to high heaven. 575 00:22:13,407 --> 00:22:14,832 Oy. 576 00:22:15,059 --> 00:22:18,577 But the judges get what the judges want. 577 00:22:18,671 --> 00:22:21,822 It's time to stack this up, so the leather goes on 578 00:22:21,916 --> 00:22:26,418 Because I need something soft to mold to my integral bolster. 579 00:22:26,571 --> 00:22:29,847 The leather does that, and then I put my bone 580 00:22:30,074 --> 00:22:32,666 And then more pieces of stacked leather. 581 00:22:32,685 --> 00:22:34,410 That way, when I peen this down, 582 00:22:34,428 --> 00:22:37,596 There is no chance of anything splitting. 583 00:22:37,748 --> 00:22:40,340 - He is using leather as a transition piece, 584 00:22:40,360 --> 00:22:41,600 Then it looks like he's gonna put a butt cap 585 00:22:41,752 --> 00:22:43,252 On the end of that. 586 00:22:43,270 --> 00:22:45,363 - Okay, so does that work? - Yeah, it'll work. 587 00:22:45,514 --> 00:22:48,366 - I know I'm gonna need that five minute epoxy to harden 588 00:22:48,517 --> 00:22:51,260 Before I get that butt cap peened on. 589 00:22:51,278 --> 00:22:54,096 ♪ ♪ 590 00:22:54,115 --> 00:22:57,023 - Well, I get the handle all fit up, and I can work 591 00:22:57,043 --> 00:22:59,543 Over the peen on the end of the knife. 592 00:22:59,695 --> 00:23:01,545 - It works better if you don't have epoxy. 593 00:23:01,697 --> 00:23:03,272 You can see that little flame pop up 594 00:23:03,290 --> 00:23:04,882 Where he's burning the glue. 595 00:23:05,033 --> 00:23:08,201 - Everything is bent over just well enough 596 00:23:08,221 --> 00:23:10,446 So I can start grinding this to shape. 597 00:23:10,464 --> 00:23:13,799 ♪ ♪ 598 00:23:13,893 --> 00:23:16,042 Ah, you [bleep]. 599 00:23:16,137 --> 00:23:18,621 - Oh. - Yeah, that's not good. 600 00:23:18,639 --> 00:23:20,956 - Unfortunately, what we've seen a lot of 601 00:23:20,975 --> 00:23:23,626 Are smiths heating things over and grinding away 602 00:23:23,719 --> 00:23:24,902 All the work that they just did. 603 00:23:29,467 --> 00:23:30,633 - The brass piece has melted the glue 'cause it got hot. 604 00:23:30,651 --> 00:23:32,484 'cause the butt cap got hot, 605 00:23:32,637 --> 00:23:33,819 And it's starting to shift. 606 00:23:33,913 --> 00:23:35,638 What can I do? 607 00:23:35,656 --> 00:23:37,973 If I don't have a really tight fit, 608 00:23:37,992 --> 00:23:39,083 Then I'm definitely going home. 609 00:23:43,238 --> 00:23:45,071 Time's running out, and I'm starting to feel 610 00:23:45,091 --> 00:23:46,999 A little bit frustrated. 611 00:23:47,093 --> 00:23:50,335 I'm gonna have to apply some superglue and hope that 612 00:23:50,430 --> 00:23:54,006 That is gonna make everything solidify a little bit. 613 00:23:54,158 --> 00:23:56,675 - Krazy glue is a quick thing to use as a filler 614 00:23:56,769 --> 00:23:59,437 But not necessarily something to hold tightly together 615 00:23:59,588 --> 00:24:01,013 Because sometimes, I've seen you guys, 616 00:24:01,165 --> 00:24:02,681 You just snap it, the vibration makes it brittle. 617 00:24:02,833 --> 00:24:04,275 - Yeah. 618 00:24:04,426 --> 00:24:06,685 - Bladesmiths, you have 20 minutes left. 619 00:24:06,779 --> 00:24:08,946 - C'est la vie. 620 00:24:09,097 --> 00:24:13,175 - I've got to have a good convex edge on my blade. 621 00:24:13,194 --> 00:24:14,935 I don't wanna go into the testing with a blade 622 00:24:14,954 --> 00:24:16,695 That's not gonna hold edge, 623 00:24:16,847 --> 00:24:18,530 But I don't want that edge to be so thin 624 00:24:18,624 --> 00:24:20,958 That it's gonna shatter or chip during the test. 625 00:24:21,109 --> 00:24:23,627 - A wood chop, it's a tough test, 626 00:24:23,854 --> 00:24:28,207 But a properly done edge, chop wood all day. 627 00:24:28,359 --> 00:24:30,859 - I've got a good, sharp, shaving blade. 628 00:24:30,878 --> 00:24:32,803 You know, I'm pretty proud of the blade that I made 629 00:24:33,030 --> 00:24:34,546 Within the timeframe that I had to do it. 630 00:24:34,640 --> 00:24:35,714 My tip's sharp. 631 00:24:35,866 --> 00:24:37,975 ♪ ♪ 632 00:24:38,126 --> 00:24:40,719 - Looks like eduardo got that tang peened over. 633 00:24:40,871 --> 00:24:42,387 - The blade's pretty much where I need it. 634 00:24:42,482 --> 00:24:45,316 And I gave a five minute epoxy enough time to harden 635 00:24:45,543 --> 00:24:48,377 So it's just straight to the grinder, 636 00:24:48,395 --> 00:24:50,229 And I'm ready to start on my handle. 637 00:24:50,323 --> 00:24:53,157 That way, it's as smooth as a transition I can get. 638 00:24:53,308 --> 00:24:54,900 There's nothing that's gonna bite the judges. 639 00:24:54,994 --> 00:24:57,328 Look at that. 640 00:24:57,479 --> 00:25:01,314 - I feel fairly confident in the construction of the blade. 641 00:25:01,334 --> 00:25:04,409 So I go ahead and start working on 642 00:25:04,504 --> 00:25:08,564 Putting an apple seed edge on and buffing things up. 643 00:25:08,582 --> 00:25:09,823 - Right now, it looks clean and shiny. 644 00:25:09,917 --> 00:25:11,008 - It looks really good. 645 00:25:11,235 --> 00:25:13,402 - My biggest concern with josh's blade 646 00:25:13,420 --> 00:25:14,845 Is that I haven't seen him 647 00:25:15,072 --> 00:25:18,423 Really go to the welder and weld up that crack. 648 00:25:18,576 --> 00:25:23,412 - Five, four, three, two, one. 649 00:25:23,505 --> 00:25:25,097 Bladesmiths, put down your tools 650 00:25:25,249 --> 00:25:26,339 And turn off your machines. 651 00:25:26,359 --> 00:25:28,100 This round of the competition is over. 652 00:25:28,252 --> 00:25:30,343 ♪ ♪ 653 00:25:30,363 --> 00:25:33,030 - My blade winds up feeling pretty nice in my hand, 654 00:25:33,181 --> 00:25:35,866 But it's an ugly pig when you look at it close. 655 00:25:36,093 --> 00:25:37,350 Hopefully, those flaws don't come back 656 00:25:37,370 --> 00:25:39,778 And bite me in the butt. 657 00:25:39,930 --> 00:25:41,446 ♪ ♪ 658 00:25:41,599 --> 00:25:43,356 - Bladesmiths, welcome to the strength test, 659 00:25:43,376 --> 00:25:45,876 The wooden gate chop. 660 00:25:46,028 --> 00:25:48,287 To test the strength and durability of the edge 661 00:25:48,439 --> 00:25:49,121 As well as the overall construction 662 00:25:49,215 --> 00:25:51,031 Of your gaucho knives, 663 00:25:51,050 --> 00:25:53,125 I'm gonna be chopping and stabbing into this here gate. 664 00:25:53,277 --> 00:25:54,534 Gary, you're up first. You ready for this? 665 00:25:54,554 --> 00:25:57,296 - Let's get it on. - All right. 666 00:25:57,448 --> 00:25:59,539 ♪ ♪ 667 00:25:59,633 --> 00:26:00,966 - When he swings the knife, his feet come off the ground, 668 00:26:01,060 --> 00:26:02,634 He hits so hard. 669 00:26:02,787 --> 00:26:04,636 So really hope that peen is good on my butt cap 670 00:26:04,789 --> 00:26:06,955 And I don't have any catastrophic failures. 671 00:26:06,974 --> 00:26:08,232 I'm more nervous than a house cat 672 00:26:08,383 --> 00:26:09,808 On a porch full of rocking chairs. 673 00:26:09,960 --> 00:26:11,068 ♪ ♪ 674 00:26:15,633 --> 00:26:20,744 ♪ ♪ 675 00:26:31,740 --> 00:26:34,592 - Well, gary, that's a good looking gaucho knife, man. 676 00:26:34,819 --> 00:26:36,576 The tip is nice and acute for stabbing, 677 00:26:36,596 --> 00:26:39,504 It held up well, and your edge also held up really well. 678 00:26:39,657 --> 00:26:41,599 So well done. - Thank you. 679 00:26:41,826 --> 00:26:42,933 - All right, eduardo, how do you feel? 680 00:26:43,160 --> 00:26:45,160 Um. Beat it like it owes you money. 681 00:26:45,179 --> 00:26:46,845 - [laughs] 682 00:26:46,997 --> 00:26:48,272 ♪ ♪ 683 00:26:48,423 --> 00:26:50,332 - I'm very nervous. 684 00:26:50,351 --> 00:26:52,443 I did quench three times. 685 00:26:52,594 --> 00:26:54,853 There is a lot of stress in my blade, 686 00:26:55,005 --> 00:26:57,448 And I'm afraid that when ben abbott strikes that fence, 687 00:26:57,599 --> 00:26:59,024 It's gonna explode. 688 00:26:59,176 --> 00:27:05,956 ♪ ♪ 689 00:27:18,286 --> 00:27:20,696 - Well, eduardo, first things first, you're all in one piece. 690 00:27:20,789 --> 00:27:22,973 Everything's still tight. Nice job. 691 00:27:23,125 --> 00:27:25,976 Your edge just hit this one spot here. 692 00:27:26,128 --> 00:27:27,645 It's just got a little bit of a glinting to it, 693 00:27:27,872 --> 00:27:29,204 But you have a relatively obtuse edge, 694 00:27:29,297 --> 00:27:30,964 So the rest of it held up great. 695 00:27:31,058 --> 00:27:34,059 Nice job. - Thank you. 696 00:27:34,153 --> 00:27:36,320 - All right, josh, you're up. You ready for this? 697 00:27:36,471 --> 00:27:37,821 - Whether I am or not, let's do it. 698 00:27:37,973 --> 00:27:40,473 - All right, let's do. 699 00:27:40,493 --> 00:27:42,475 - My biggest concern going into testing 700 00:27:42,495 --> 00:27:45,387 Is really that the handle holds up, 701 00:27:45,406 --> 00:27:49,224 It doesn't wiggle apart, doesn't rotate in their hands. 702 00:27:49,243 --> 00:27:56,006 ♪ ♪ 703 00:28:09,689 --> 00:28:12,581 - Well, josh, it held up great, so nice job on that. 704 00:28:12,599 --> 00:28:15,859 The crack you had in your steel is still present, 705 00:28:16,011 --> 00:28:17,844 Which is now kind of full of sawdust. 706 00:28:17,863 --> 00:28:20,756 But it's not opening up; I didn't see it move anywhere. 707 00:28:20,774 --> 00:28:22,849 Your blade kind of meanders, 708 00:28:22,868 --> 00:28:24,868 It's sort of starts off going left 709 00:28:25,020 --> 00:28:27,705 And then kind of curves riding in and then rights itself. 710 00:28:27,856 --> 00:28:30,874 When coupled with a handle that's pretty round, 711 00:28:31,026 --> 00:28:33,877 I did have to adjust once or twice to get it back on line, 712 00:28:34,029 --> 00:28:35,379 But in general, you held up well on the strength test, 713 00:28:35,530 --> 00:28:36,455 And nice job. 714 00:28:36,607 --> 00:28:38,106 - Thank you. 715 00:28:38,125 --> 00:28:41,944 ♪ ♪ 716 00:28:42,037 --> 00:28:43,703 - Welcome to the sharpness test, 717 00:28:43,797 --> 00:28:45,464 The gaucho blanket slice. 718 00:28:45,616 --> 00:28:47,616 ♪ ♪ 719 00:28:47,634 --> 00:28:48,800 Now to find out how sharp your weapons are, 720 00:28:48,953 --> 00:28:51,787 I'm gonna cut through these gaucho blankets. 721 00:28:51,880 --> 00:28:53,288 Gary, you're up first, ready for this? 722 00:28:53,307 --> 00:28:54,639 - I'm ready. - Lets do this. 723 00:28:54,792 --> 00:29:00,904 ♪ ♪ 724 00:29:16,238 --> 00:29:18,571 All right, gary, let's talk about your gaucho knife here. 725 00:29:18,665 --> 00:29:19,906 Your edge is sharp. 726 00:29:20,000 --> 00:29:21,650 Now it may look like rips; 727 00:29:21,743 --> 00:29:24,077 Those are actually very clean cuts. 728 00:29:24,096 --> 00:29:26,505 Overall, sir, your weapon, it will cut. 729 00:29:26,657 --> 00:29:28,432 - Thank you. 730 00:29:28,583 --> 00:29:30,158 - All right, eduardo, your turn, so are you ready? 731 00:29:30,252 --> 00:29:31,435 - Yes, sir. - Let's do this. 732 00:29:33,163 --> 00:29:39,401 ♪ ♪ 733 00:29:49,863 --> 00:29:50,770 - All right, eduardo, let's talk about 734 00:29:50,864 --> 00:29:52,790 Your gaucho knife here. 735 00:29:52,941 --> 00:29:54,533 Even though you have an obtuse grind, 736 00:29:54,685 --> 00:29:57,795 It cut easily through this gaucho blanket. 737 00:29:57,946 --> 00:30:00,964 Overall, sir, your weapon, it will cut. 738 00:30:01,116 --> 00:30:02,357 - Thank you so much. 739 00:30:02,450 --> 00:30:03,783 - Josh, your turn, so you ready? 740 00:30:03,877 --> 00:30:06,211 - Yee-haw. - Yee-haw. 741 00:30:06,363 --> 00:30:13,143 ♪ ♪ 742 00:30:24,323 --> 00:30:25,989 All right, josh, let's talk about your gaucho knife here. 743 00:30:26,141 --> 00:30:29,642 Now your edge also has an obtuse grind. 744 00:30:29,736 --> 00:30:33,497 But it is sharp enough to cut cleanly into this blanket. 745 00:30:33,648 --> 00:30:35,982 Overall, sir, your weapon, it will cut. 746 00:30:36,001 --> 00:30:39,077 - Thank you, sir. 747 00:30:39,229 --> 00:30:40,579 - All right bladesmiths, well, the gaucho knife challenge 748 00:30:40,731 --> 00:30:42,655 Was definitely a difficult one. 749 00:30:42,749 --> 00:30:46,343 But you all gave us blades that made easy work of our testing. 750 00:30:46,494 --> 00:30:48,161 But in this competition, only two of you can join us 751 00:30:48,180 --> 00:30:50,330 In the third round and our judges, 752 00:30:50,349 --> 00:30:52,015 They made a decision. 753 00:30:52,167 --> 00:30:53,592 The bladesmith leaving the forge is... 754 00:30:53,744 --> 00:30:55,018 ♪ ♪ 755 00:30:55,245 --> 00:30:56,520 Josh. 756 00:30:56,747 --> 00:30:58,689 You fought hard, and you gave us a blade, 757 00:30:58,840 --> 00:31:00,691 But unfortunately it didn't make the cut today. 758 00:31:00,842 --> 00:31:02,693 And ben abbott's gonna tell you why. 759 00:31:02,844 --> 00:31:04,027 - Well, josh, you came out of round one 760 00:31:04,254 --> 00:31:05,770 With a pretty severe crack in your blade. 761 00:31:05,923 --> 00:31:08,256 And you did a great job in minimizing that crack, 762 00:31:08,275 --> 00:31:10,759 But you didn't remove it completely. 763 00:31:10,777 --> 00:31:12,536 And in doing that, you really made your blade 764 00:31:12,763 --> 00:31:14,946 Take quite a bit of warping and wobbling, 765 00:31:15,040 --> 00:31:17,040 And it's for those reasons we're gonna let you go. 766 00:31:17,192 --> 00:31:19,692 - I totally understand that. Thank you so much. 767 00:31:19,712 --> 00:31:21,603 - Well, josh, we all wanna say you're a talented smith 768 00:31:21,622 --> 00:31:23,455 And you have what it takes to be in this forge, 769 00:31:23,549 --> 00:31:25,957 But unfortunately, your time in this competition has ended. 770 00:31:26,110 --> 00:31:27,033 I'm gonna have to ask you to please 771 00:31:27,127 --> 00:31:28,126 Step off the forge floor. 772 00:31:28,278 --> 00:31:30,888 ♪ ♪ 773 00:31:31,115 --> 00:31:32,781 - I've got that little disappointment 774 00:31:32,799 --> 00:31:35,041 That I'm not able to move on and really do something 775 00:31:35,060 --> 00:31:37,561 Spectacular with a historic blade. 776 00:31:37,788 --> 00:31:39,563 But at the same time, it surprised me 777 00:31:39,790 --> 00:31:41,973 All to pieces how well my blade performed. 778 00:31:42,126 --> 00:31:43,734 ♪ ♪ 779 00:31:43,885 --> 00:31:45,794 - All right, gary, eduardo, congratulations, guys. 780 00:31:45,812 --> 00:31:47,462 Your hard work has paid off, 781 00:31:47,481 --> 00:31:49,555 And it is now down to the two of you battling it out 782 00:31:49,575 --> 00:31:51,483 For the title of "forged in fire" champion 783 00:31:51,635 --> 00:31:53,410 And that check for 10 grand. 784 00:31:53,561 --> 00:31:56,138 Now because this competition is all about iconic weapons 785 00:31:56,156 --> 00:31:57,748 From south america, we're sticking with that theme. 786 00:31:57,975 --> 00:32:00,325 We're giving you four days to build this... 787 00:32:00,477 --> 00:32:02,920 ♪ ♪ 788 00:32:05,090 --> 00:32:08,741 The argentinian saber. 789 00:32:08,835 --> 00:32:11,169 - The argentinian saber was a fierce 19th century weapon 790 00:32:11,321 --> 00:32:12,763 Used by the cavalry soldiers 791 00:32:12,914 --> 00:32:15,507 Known as the argentinian grenadiers. 792 00:32:15,601 --> 00:32:17,159 These mounted warriors used the lightweight 793 00:32:17,177 --> 00:32:18,827 Single edged blade to deliver swift 794 00:32:18,845 --> 00:32:20,996 And lethal slashes against enemies 795 00:32:21,014 --> 00:32:23,423 While the large hilt protected their hands. 796 00:32:23,442 --> 00:32:24,942 After their crucial service 797 00:32:25,169 --> 00:32:27,093 In the argentinian war of independence, 798 00:32:27,112 --> 00:32:28,520 The grenadiers were given the honor 799 00:32:28,614 --> 00:32:31,431 Of becoming the presidential escort guard. 800 00:32:31,525 --> 00:32:33,617 Today, these elite soldiers still protect the president 801 00:32:33,844 --> 00:32:36,787 With this powerful saber at their sides. 802 00:32:36,938 --> 00:32:39,289 - Your blades need to have a slightly curved pipeback blade 803 00:32:39,441 --> 00:32:41,792 That measures between 35 and 37 inches. 804 00:32:41,943 --> 00:32:43,293 Now down to the hilt, 805 00:32:43,445 --> 00:32:44,962 You guys need to have an asymmetrical 806 00:32:45,113 --> 00:32:47,613 Bell-shaped guard with multiple piercings. 807 00:32:47,708 --> 00:32:52,043 And to finish it off, you need to have a pistol grip handle. 808 00:32:52,196 --> 00:32:54,045 - I've never forged anything this long, 809 00:32:54,198 --> 00:32:56,381 But I'm gonna make the best argentinian saber 810 00:32:56,533 --> 00:33:00,552 Because I wanna win so bad I can taste it. 811 00:33:00,704 --> 00:33:02,795 - All right, guys, we will see you in four days. 812 00:33:02,815 --> 00:33:05,223 - Good luck. - Well, stay safe, dude. 813 00:33:05,375 --> 00:33:08,210 ♪ ♪ 814 00:33:08,303 --> 00:33:10,045 - I'm here in my home forge, 815 00:33:10,063 --> 00:33:11,971 Ready to make an argentinian saber. 816 00:33:11,991 --> 00:33:14,065 Alrighty. Here we go. 817 00:33:14,159 --> 00:33:16,660 My goal for today is to have a hardened blade 818 00:33:16,887 --> 00:33:18,236 Ready to start grinding on it tomorrow 819 00:33:18,388 --> 00:33:19,404 And starting to make it pretty. 820 00:33:19,556 --> 00:33:21,406 My concern is the pipeback spine. 821 00:33:21,558 --> 00:33:22,982 There we go. 822 00:33:23,002 --> 00:33:25,393 I never knew that existed until today. 823 00:33:25,412 --> 00:33:27,337 The biggest challenge is putting in the curve 824 00:33:27,489 --> 00:33:29,064 That's a requirement 825 00:33:29,082 --> 00:33:30,841 While still keeping the pipeback spine intact. 826 00:33:34,013 --> 00:33:36,588 Forging has gone really well. That's good enough. 827 00:33:36,740 --> 00:33:39,257 It's close enough, and I am ready for the quench. 828 00:33:39,409 --> 00:33:41,518 ♪ ♪ 829 00:33:41,745 --> 00:33:44,187 Whew. 830 00:33:44,339 --> 00:33:45,856 The blade is hard. 831 00:33:46,083 --> 00:33:49,251 The blade is straight. And I'm exhausted. 832 00:33:49,269 --> 00:33:54,773 ♪ ♪ 833 00:33:54,867 --> 00:33:56,925 - I'm here in my home shop in elkmont, alabama. 834 00:33:57,018 --> 00:33:57,850 I'm getting ready to get started 835 00:33:57,944 --> 00:33:59,427 On the argentinian saber. 836 00:33:59,446 --> 00:34:02,188 Mississippi 5160. 837 00:34:02,207 --> 00:34:05,100 By the end of day one, I wanna have my blade forged out. 838 00:34:05,118 --> 00:34:07,435 Then stretch the rod out a little bit. 839 00:34:07,454 --> 00:34:09,287 You see the pipe coming out. 840 00:34:09,381 --> 00:34:11,197 So far, so good. 841 00:34:11,216 --> 00:34:12,957 A forged blade out that the length I want out of it, 842 00:34:13,110 --> 00:34:14,125 You gotta force the shape. 843 00:34:14,278 --> 00:34:15,627 Drawing it out with my dies 844 00:34:15,779 --> 00:34:17,387 And verify that everything's nice and even. 845 00:34:17,539 --> 00:34:19,890 It's looking good. 846 00:34:20,041 --> 00:34:22,801 - Day three, yesterday was fantastic. 847 00:34:22,953 --> 00:34:25,287 I got the blade completely done. 848 00:34:25,305 --> 00:34:27,789 All I need to do now is get started on my hilt, 849 00:34:27,808 --> 00:34:29,215 And one of the parameters 850 00:34:29,234 --> 00:34:31,234 Is drilling the piercings in the hilt. 851 00:34:31,386 --> 00:34:32,977 There's that disk. 852 00:34:33,130 --> 00:34:34,720 These rotary discs are literally exploding 853 00:34:34,815 --> 00:34:36,556 As soon as I put them on. 854 00:34:36,650 --> 00:34:37,908 The guard is too hard 855 00:34:38,059 --> 00:34:39,576 For the rotary discs to cut through. 856 00:34:41,246 --> 00:34:43,321 [groans] 857 00:34:43,473 --> 00:34:46,917 This one line right there took 2 1/2 cutting discs. 858 00:34:47,068 --> 00:34:49,252 I am extremely aggravated by this. 859 00:34:51,648 --> 00:34:53,481 This is supposed to be quick and easy. 860 00:34:53,500 --> 00:34:54,999 I am burning through my day. 861 00:34:55,152 --> 00:34:56,593 ♪ ♪ 862 00:34:56,744 --> 00:34:57,986 I'm falling behind. 863 00:34:58,004 --> 00:35:00,655 I hope I'm gonna have enough time. 864 00:35:00,748 --> 00:35:03,174 Alrighty, now to make that pretty. 865 00:35:03,268 --> 00:35:06,828 I finally finish the piercings on my guard. 866 00:35:06,921 --> 00:35:11,015 I am down to a single rotary disc left, 867 00:35:11,168 --> 00:35:12,609 But I'm running out of time. 868 00:35:12,836 --> 00:35:14,760 I need to fly through my handle. 869 00:35:14,780 --> 00:35:16,780 Hopefully, everything's gonna marry up perfectly. 870 00:35:16,931 --> 00:35:18,448 That's it. 871 00:35:18,675 --> 00:35:21,343 Overall, I'm still on schedule somehow. 872 00:35:21,361 --> 00:35:22,935 ♪ ♪ 873 00:35:22,955 --> 00:35:24,679 - Starting day three. 874 00:35:24,698 --> 00:35:26,623 Yesterday, I got my blade finished and quenched. 875 00:35:26,774 --> 00:35:29,126 It's time to go and sharpen the blade. 876 00:35:29,277 --> 00:35:30,460 So I'm at the point now I can go out 877 00:35:30,612 --> 00:35:32,203 And do some testing with my blade. 878 00:35:32,356 --> 00:35:34,297 ♪ ♪ 879 00:35:34,524 --> 00:35:37,709 Whoops. Missed part of it. I bent my blade. 880 00:35:37,803 --> 00:35:40,119 I come out with a blade looking like a boomerang. 881 00:35:40,213 --> 00:35:42,046 I can't salvage this blade 882 00:35:42,199 --> 00:35:43,865 Because I don't wanna risk any grain growth in the blade. 883 00:35:43,958 --> 00:35:45,642 And now I got to start over. 884 00:35:45,869 --> 00:35:47,293 I only got one more day to get it done. 885 00:35:47,312 --> 00:35:49,479 Hopefully, that's enough time to forge a new blade. 886 00:35:54,153 --> 00:35:55,226 - We should have the process down pat now. 887 00:35:55,379 --> 00:35:56,469 ♪ ♪ 888 00:35:56,563 --> 00:35:58,137 We're good on parameters. 889 00:35:58,231 --> 00:35:59,714 It's been a hell of a day, 890 00:35:59,733 --> 00:36:02,066 But at the end, I've got a quenched blade. 891 00:36:02,219 --> 00:36:03,809 This blade looks a lot better than the blade 892 00:36:03,904 --> 00:36:05,328 That didn't work out so great. 893 00:36:05,480 --> 00:36:07,647 All right. 894 00:36:07,741 --> 00:36:10,074 - Morning of day four and it's time for some fit and finish. 895 00:36:10,227 --> 00:36:13,336 ♪ ♪ 896 00:36:13,488 --> 00:36:15,839 After I peen this on and close it, 897 00:36:16,066 --> 00:36:19,342 I'm gonna grind this extra steel off 898 00:36:19,569 --> 00:36:23,847 So it's a much tighter fit to the handle. 899 00:36:23,998 --> 00:36:27,833 It's time to peen the guard and then sharpen my blade. 900 00:36:27,853 --> 00:36:29,577 That should be it. 901 00:36:29,596 --> 00:36:31,021 It's really coming out great. 902 00:36:31,172 --> 00:36:34,916 That is sharp. 903 00:36:34,935 --> 00:36:37,419 - Day four, I feel I'm in pretty good shape. 904 00:36:37,437 --> 00:36:39,845 It's time for me to work on my handle and my hilt. 905 00:36:39,940 --> 00:36:42,273 I grab a piece of sheet metal, cut out the shape that I want, 906 00:36:42,426 --> 00:36:45,035 Then I start shaping it in the swage block. 907 00:36:45,186 --> 00:36:48,038 Now I'm gonna cut these piercings into my hilt. 908 00:36:48,189 --> 00:36:49,764 My plan to put this handle together 909 00:36:49,783 --> 00:36:51,190 And secure it properly is, 910 00:36:51,210 --> 00:36:53,435 Is I wanna notch out my tang, 911 00:36:53,453 --> 00:36:55,103 Weld in a machine bolt with a spacer 912 00:36:55,121 --> 00:36:57,047 So I can tighten it all up. 913 00:36:57,198 --> 00:36:58,440 And the last thing I need to do 914 00:36:58,533 --> 00:37:00,291 Is sharpen it and assemble the sword. 915 00:37:00,444 --> 00:37:03,294 That's it for round three. It's in the judges hands now. 916 00:37:03,447 --> 00:37:09,617 ♪ ♪ 917 00:37:09,636 --> 00:37:11,377 - Welcome back to the forge. 918 00:37:11,471 --> 00:37:13,955 You just stepped in here after four days at your home forges 919 00:37:13,974 --> 00:37:16,900 Working on your very best argentinian sabers. 920 00:37:17,051 --> 00:37:19,903 But before we get into testing, I wanna hear about the blades. 921 00:37:20,054 --> 00:37:23,055 Gary, how'd it go for you? 922 00:37:23,075 --> 00:37:24,482 - I started hitting some bumps, 923 00:37:24,634 --> 00:37:27,151 And I made the decision to forge another blade. 924 00:37:27,304 --> 00:37:30,080 I used 5160 for the blade, sheet metal for the guard, 925 00:37:30,307 --> 00:37:31,806 And some mystery wood for the handle. 926 00:37:31,825 --> 00:37:33,566 - Eduardo, how about you, how'd it go? 927 00:37:33,585 --> 00:37:35,994 - Very stressful. Lots of unknowns but good. 928 00:37:36,146 --> 00:37:37,645 ♪ ♪ 929 00:37:37,739 --> 00:37:39,923 I used 80crv2 for my blade, 930 00:37:40,150 --> 00:37:42,150 14 gauge steel for my bell guard, 931 00:37:42,168 --> 00:37:43,985 And padauk for my handle. 932 00:37:44,004 --> 00:37:45,244 I can't wait for you guys to mutilate it. 933 00:37:45,338 --> 00:37:46,763 - [chuckles] - awesome. 934 00:37:46,914 --> 00:37:48,840 Gentlemen, your blades look lethal. 935 00:37:48,934 --> 00:37:50,249 There's only one way we know how to find out 936 00:37:50,269 --> 00:37:51,935 Which one of you is gonna be leaving here 937 00:37:52,162 --> 00:37:53,919 With the title of "forged in fire" champion, 938 00:37:53,939 --> 00:37:55,921 And that's by putting your blades through some tests. 939 00:37:56,016 --> 00:37:57,665 First, the keal with doug. 940 00:37:57,684 --> 00:38:01,169 ♪ ♪ 941 00:38:01,187 --> 00:38:04,506 - All right, bladesmiths, welcome to the keal test. 942 00:38:04,524 --> 00:38:05,523 Well, it's time to find out 943 00:38:05,675 --> 00:38:07,117 Just how lethal your weapons are. 944 00:38:07,268 --> 00:38:09,511 I'm gonna take your weapons and deliver some thrusts 945 00:38:09,604 --> 00:38:11,679 And slashes on this pig carcass. 946 00:38:11,698 --> 00:38:12,938 Gary, you're up first. Are you ready for this? 947 00:38:12,958 --> 00:38:14,291 - I'm ready. - Let's do this. 948 00:38:18,872 --> 00:38:20,355 - Since I've already warped one blade during testing at home, 949 00:38:20,373 --> 00:38:21,464 During testing at home, 950 00:38:21,616 --> 00:38:22,448 I'm nervous as a cat on a hot tin roof. 951 00:38:22,542 --> 00:38:23,541 A pig's a tough animal, 952 00:38:23,693 --> 00:38:25,043 And I don't want my blade to crack. 953 00:38:25,137 --> 00:38:27,211 I don't want it to warp, and I don't want it to break. 954 00:38:27,364 --> 00:38:33,935 ♪ ♪ 955 00:38:57,169 --> 00:38:59,077 - All right, gary, let's talk about your weapon here. 956 00:38:59,229 --> 00:39:00,503 First up, most of the weight 957 00:39:00,730 --> 00:39:03,823 Is right in the very tip of this blade. 958 00:39:03,917 --> 00:39:06,158 But the saving grace for that is that you have a nice handle 959 00:39:06,178 --> 00:39:08,511 Right there where I can grab on to it. 960 00:39:08,663 --> 00:39:11,089 I can marry my hand, it's all void, 961 00:39:11,241 --> 00:39:13,424 And I've got full control with this weapon. 962 00:39:13,577 --> 00:39:16,744 As you can see, those were very deep cuts. 963 00:39:16,763 --> 00:39:18,262 Overall, sir, your weapon... 964 00:39:18,415 --> 00:39:19,931 ♪ ♪ 965 00:39:20,025 --> 00:39:21,191 It will keal. 966 00:39:21,418 --> 00:39:23,101 - Thank you. 967 00:39:23,195 --> 00:39:24,361 - All right, eduardo, your turn, so are you ready? 968 00:39:24,512 --> 00:39:25,603 - I'm excited. Let's go. 969 00:39:25,697 --> 00:39:27,346 - Let's do this. 970 00:39:27,440 --> 00:39:29,532 - I know my edge is fantastic. 971 00:39:29,684 --> 00:39:32,184 It can take a beating. It's a killer blade. 972 00:39:32,204 --> 00:39:33,611 I can't wait to see what it can do. 973 00:39:33,763 --> 00:39:40,502 ♪ ♪ 974 00:39:45,050 --> 00:39:46,866 - Gentlemen, I think we have a problem here. 975 00:39:46,885 --> 00:39:50,870 That's a very small handle. My hand barely fits in there. 976 00:39:50,889 --> 00:39:52,722 And when I'm swinging, 977 00:39:52,949 --> 00:39:55,950 There was just no retention or stop right here. 978 00:39:55,969 --> 00:39:57,969 Especially in the slashes. 979 00:39:58,121 --> 00:39:59,896 If you're thrusting it with a forward width, 980 00:40:00,047 --> 00:40:02,214 All that is on my wrist. 981 00:40:02,234 --> 00:40:03,808 What do you think? 982 00:40:03,960 --> 00:40:05,627 - I see what you're saying. 983 00:40:05,645 --> 00:40:07,311 I can swing it out, but I can't pull it back up 984 00:40:07,464 --> 00:40:08,813 'cause I don't have the leverage. 985 00:40:08,965 --> 00:40:11,574 - Yeah, I'm looking at my fingers doubled up. 986 00:40:11,726 --> 00:40:13,651 The problem is, is there's no space in there. 987 00:40:13,803 --> 00:40:16,154 If it does cut loose, that's breaking my hand. 988 00:40:16,306 --> 00:40:18,322 - Is there any way to adjust and make it fair? 989 00:40:18,475 --> 00:40:20,733 - The problem with that is, I can hold back 990 00:40:20,752 --> 00:40:22,919 To make it work, but now I'm holding back, 991 00:40:23,146 --> 00:40:24,904 And that's not an even test anymore. 992 00:40:24,923 --> 00:40:27,239 - Okay, you guys all agree the blade is not safe to wield? 993 00:40:27,333 --> 00:40:28,650 - Yes. - Definitely. 994 00:40:28,668 --> 00:40:29,592 - Okay. 995 00:40:29,744 --> 00:40:30,985 - [bleep]. 996 00:40:31,004 --> 00:40:33,245 ♪ ♪ 997 00:40:33,265 --> 00:40:35,080 - Eduardo, we absolutely hate 998 00:40:35,100 --> 00:40:36,507 To see a competition end like this. 999 00:40:36,660 --> 00:40:38,751 When wielding an edged weapon, 1000 00:40:38,770 --> 00:40:41,104 Safety is always of the utmost importance. 1001 00:40:41,255 --> 00:40:43,665 Due to the small handle you've presented 1002 00:40:43,683 --> 00:40:45,333 And the lack of retention that it offers, 1003 00:40:45,351 --> 00:40:47,168 The judges have issued a vote of no confidence. 1004 00:40:47,261 --> 00:40:49,094 They can't safely test your weapon. 1005 00:40:49,114 --> 00:40:52,006 So unfortunately, your time in this competition has ended. 1006 00:40:52,099 --> 00:40:52,857 I'm gonna have to ask you to please 1007 00:40:53,009 --> 00:40:54,192 Step off the forge floor. 1008 00:40:54,344 --> 00:40:55,677 ♪ ♪ 1009 00:40:55,770 --> 00:40:57,102 - Congratulations, buddy. - Thanks. 1010 00:40:57,122 --> 00:40:58,362 - Thank you, though, eduardo. 1011 00:40:58,515 --> 00:41:00,348 ♪ ♪ 1012 00:41:00,441 --> 00:41:03,275 - I'm crushed. I'm disappointed. 1013 00:41:03,369 --> 00:41:05,444 I worked really hard for it for it to not to get tested. 1014 00:41:05,538 --> 00:41:07,797 It fit my hand perfectly. 1015 00:41:07,949 --> 00:41:10,967 Every step of this competition was a learning experience, 1016 00:41:11,118 --> 00:41:13,544 And I really think I'm leaving a better smith. 1017 00:41:13,697 --> 00:41:16,380 ♪ ♪ 1018 00:41:16,475 --> 00:41:18,641 - Gary, you are today's "forged in fire" champion. 1019 00:41:18,793 --> 00:41:20,643 You got yourself a check for $10,000. 1020 00:41:20,795 --> 00:41:22,036 Congratulations. 1021 00:41:22,055 --> 00:41:24,222 - Thank you. I really appreciate it. 1022 00:41:24,374 --> 00:41:25,965 It feels great to be a "forged in fire" champion. 1023 00:41:25,984 --> 00:41:27,150 - What are you gonna do with the 10 grand? 1024 00:41:27,377 --> 00:41:28,559 Do you have plans? - No, I'm sure my wife does. 1025 00:41:28,653 --> 00:41:30,228 [laughter] 1026 00:41:30,380 --> 00:41:31,821 I just want to savor this for a while. 1027 00:41:31,973 --> 00:41:33,881 It was a lot of work to get here. 1028 00:41:33,900 --> 00:41:35,900 It's been fun, I've met a lot of great people, 1029 00:41:36,052 --> 00:41:37,735 And I've enjoyed it. 1030 00:41:37,887 --> 00:41:42,624 ♪ ♪