1 00:00:01,744 --> 00:00:04,670 [dramatic music] 2 00:00:04,897 --> 00:00:07,247 ♪ ♪ 3 00:00:07,341 --> 00:00:10,158 - Here in the forge, we are always raising the ba, 4 00:00:10,177 --> 00:00:12,678 But now we are putting it at an all-time high. 5 00:00:12,905 --> 00:00:14,238 ♪ ♪ 6 00:00:14,331 --> 00:00:15,739 Everything in this competition, 7 00:00:15,832 --> 00:00:18,258 From the steel, the blades, even the test 8 00:00:18,352 --> 00:00:19,760 Will be some of the biggest 9 00:00:19,854 --> 00:00:22,429 We have ever seen on the forge floor. 10 00:00:22,581 --> 00:00:24,690 - That's a big piece of steel. - [laughs] 11 00:00:24,917 --> 00:00:26,674 - Who will rise to this massive challenge 12 00:00:26,769 --> 00:00:29,344 And take home $10,000? 13 00:00:29,438 --> 00:00:31,530 - Big knife, big challenge. 14 00:00:31,757 --> 00:00:34,441 - This is "forged in fire: Supersized." 15 00:00:34,535 --> 00:00:36,201 [glass shatters] 16 00:00:36,428 --> 00:00:39,780 ♪ ♪ 17 00:00:39,932 --> 00:00:42,599 - My name is eland green. I am 26 years old. 18 00:00:42,618 --> 00:00:44,935 I am a part-time bladesmith out of callisburg, texas. 19 00:00:44,953 --> 00:00:48,380 I got into bladesmithing with a whole lot 20 00:00:48,607 --> 00:00:49,882 Of internet surfing. 21 00:00:50,109 --> 00:00:51,884 I ended up getting my grandpa involved. 22 00:00:52,111 --> 00:00:54,294 We watch "forged in fire" every day. 23 00:00:54,446 --> 00:00:56,129 And being able to say, 24 00:00:56,282 --> 00:00:58,448 "hey, grandpa, I got on 'forged in fire'" 25 00:00:58,542 --> 00:01:00,225 And I know he'll be proud of that. 26 00:01:00,452 --> 00:01:02,043 ♪ ♪ 27 00:01:02,137 --> 00:01:04,546 - My name's clay unruh, and I'm from coldwater, kansas. 28 00:01:04,640 --> 00:01:08,567 I'm 30 years old, and I've been bladesmithing about five years. 29 00:01:08,718 --> 00:01:10,977 I like making really weird stuff. 30 00:01:11,072 --> 00:01:15,223 I've always been into fantasy movies and video games. 31 00:01:15,317 --> 00:01:18,744 I've made a zombie apocalypse axe 32 00:01:18,895 --> 00:01:21,914 With, like, a bat for the handle. 33 00:01:22,141 --> 00:01:24,324 I'm here to prove that I'm not just another guy 34 00:01:24,418 --> 00:01:26,919 Making knives in his garage. I can hang with the big dogs. 35 00:01:27,146 --> 00:01:28,662 ♪ ♪ 36 00:01:28,814 --> 00:01:29,996 - My name is josh meyer 37 00:01:30,091 --> 00:01:32,833 And I'm 47 years old from flagstaff, arizona. 38 00:01:32,985 --> 00:01:34,409 And I've been smithing for about five years. 39 00:01:34,503 --> 00:01:35,986 My biggest strength in smithing 40 00:01:36,079 --> 00:01:38,079 Is probably the variety of things I do 41 00:01:38,173 --> 00:01:39,840 'cause I'm not just a bladesmith, 42 00:01:39,992 --> 00:01:41,916 I'm a full-time artist. 43 00:01:41,936 --> 00:01:44,770 I work primarily in the mediums of stone, steel, and wood. 44 00:01:44,997 --> 00:01:47,848 ♪ ♪ 45 00:01:48,000 --> 00:01:49,499 - My name is rob harvey. 46 00:01:49,593 --> 00:01:51,276 I'm from charlotte, north carolina. 47 00:01:51,503 --> 00:01:53,428 I work for the department of veterans affairs, 48 00:01:53,522 --> 00:01:55,614 And I'm a part-time bladesmith. 49 00:01:55,765 --> 00:01:59,100 I was in the marine corps, and I actually spent 50 00:01:59,194 --> 00:02:01,936 Most of my time in okinawa, japan. 51 00:02:02,030 --> 00:02:03,680 I definitely take influence 52 00:02:03,699 --> 00:02:06,183 From the japanese style of bladesmithing. 53 00:02:06,201 --> 00:02:08,627 I had a great respect for visiting the shops in japan. 54 00:02:08,854 --> 00:02:11,188 ♪ ♪ 55 00:02:11,206 --> 00:02:13,874 - Well, gentlemen, welcome to the forge. 56 00:02:13,968 --> 00:02:16,135 The four of you are here to put your skills to the test 57 00:02:16,286 --> 00:02:18,879 In a massive bladesmithing competition. 58 00:02:18,973 --> 00:02:21,531 This consists of three rounds. At the end of each one, 59 00:02:21,625 --> 00:02:22,549 I will ask you to present your work 60 00:02:22,643 --> 00:02:24,292 To our panel of expert judges. 61 00:02:24,386 --> 00:02:25,218 And they're the ones who will decide 62 00:02:25,312 --> 00:02:26,979 Who leaves here empty-handed, 63 00:02:27,206 --> 00:02:30,040 Who's taking home the title and that check for 10 grand. 64 00:02:30,133 --> 00:02:32,467 Now, bladesmiths, this is a competition 65 00:02:32,486 --> 00:02:35,896 In the series we are calling "forged in fire: Supersized." 66 00:02:36,048 --> 00:02:37,322 Now, bladesmiths, under this tarp 67 00:02:37,549 --> 00:02:40,901 I've got not one, but two massive pieces of steel 68 00:02:40,995 --> 00:02:42,477 With which we want you 69 00:02:42,571 --> 00:02:44,888 To salvage materials to make blades. 70 00:02:44,981 --> 00:02:46,498 Now, I'm sure you guys are ready 71 00:02:46,650 --> 00:02:47,908 To light the forges and get going. 72 00:02:48,060 --> 00:02:49,150 - Yes, sir. 73 00:02:49,244 --> 00:02:51,003 - So you guys are gonna need these. 74 00:02:51,230 --> 00:02:57,234 ♪ ♪ 75 00:02:57,327 --> 00:02:59,753 - I see these massive coil springs 76 00:02:59,847 --> 00:03:02,664 That look like dinosaur bones, 77 00:03:02,683 --> 00:03:06,092 And I don't know how you can draw that out in three hours. 78 00:03:06,187 --> 00:03:07,411 - Bladesmiths, what you're looking at here 79 00:03:07,504 --> 00:03:11,581 Is 500 combined pounds of 5160 spring. 80 00:03:11,675 --> 00:03:13,192 In addition to the spring steel, 81 00:03:13,419 --> 00:03:16,344 You then take the steel, clad it over your spring 82 00:03:16,438 --> 00:03:18,271 To make a san mai billet. 83 00:03:18,424 --> 00:03:20,515 With which we want you to make a massive signature blade 84 00:03:20,609 --> 00:03:24,778 In your signature style between 16 and 18 inches. 85 00:03:24,872 --> 00:03:27,355 - Big knife, big challenge. 86 00:03:27,449 --> 00:03:29,708 It's definitely, definitely supersized. 87 00:03:29,935 --> 00:03:31,451 ♪ ♪ 88 00:03:31,603 --> 00:03:33,212 - Now, for the three of you who are lucky enough 89 00:03:33,439 --> 00:03:35,047 To join us in the second round of competition, 90 00:03:35,274 --> 00:03:36,773 You will add handles to those signature blades 91 00:03:36,792 --> 00:03:38,608 Turning them into fully functioning weapons 92 00:03:38,627 --> 00:03:40,201 At which point our judges will put them 93 00:03:40,295 --> 00:03:41,778 Through a series of tests. 94 00:03:41,871 --> 00:03:43,280 You're gonna start off by checking your strength 95 00:03:43,373 --> 00:03:45,224 And durability in an ice block chop 96 00:03:45,451 --> 00:03:46,541 And then check your edger tension 97 00:03:46,635 --> 00:03:48,894 In a double punching bag slice. 98 00:03:49,121 --> 00:03:50,896 All right, guys, we've got three hours on the clock 99 00:03:51,047 --> 00:03:52,956 For the first round of this supersized competition, 100 00:03:53,049 --> 00:03:55,901 So good luck, stay sharp. Your time starts now. 101 00:03:56,128 --> 00:03:57,627 ♪ ♪ 102 00:03:57,646 --> 00:03:58,645 - Yeah, they're really springing to it. 103 00:03:58,739 --> 00:04:00,072 - Yeah, really. - [laughs] 104 00:04:00,223 --> 00:04:02,574 - It's a big piece of steel. [laughs] 105 00:04:02,801 --> 00:04:04,818 - It literally takes two guys to move them. 106 00:04:04,912 --> 00:04:06,653 They're gonna have a heck of a time breaking this down 107 00:04:06,747 --> 00:04:09,230 And getting the steel they need for their core materia. 108 00:04:09,324 --> 00:04:10,657 - As soon as the clock starts, 109 00:04:10,809 --> 00:04:13,477 Me and eland are teaming up for the greater good 110 00:04:13,570 --> 00:04:16,404 And getting our pieces of steel harvest. 111 00:04:16,423 --> 00:04:17,981 - Both of our springs are getting attacked 112 00:04:18,074 --> 00:04:19,816 With the oxy acetylene torches. You guys think 113 00:04:19,909 --> 00:04:21,501 That's the fastest method to get this broken down? 114 00:04:21,595 --> 00:04:22,652 - If you know how to use 115 00:04:22,746 --> 00:04:23,670 An oxy acetylene cutting torch it is. 116 00:04:23,764 --> 00:04:25,580 - Don't cut my foot. [laughs] 117 00:04:25,599 --> 00:04:28,825 I'm nervous. I've made san mai in the past 118 00:04:28,918 --> 00:04:31,177 But never with something so large. 119 00:04:31,272 --> 00:04:32,771 - So bare minimum, 120 00:04:32,998 --> 00:04:34,773 What can they get away with on this spring? 121 00:04:35,000 --> 00:04:36,591 - I wouldn't go much less than three inches. 122 00:04:36,685 --> 00:04:38,835 - Okay. - You can always lose steal, 123 00:04:38,928 --> 00:04:42,339 But not having enough in the san mai situation, 124 00:04:42,432 --> 00:04:44,024 30 minutes, 40 minutes, an hour from now 125 00:04:44,118 --> 00:04:45,117 You're starting over. 126 00:04:45,344 --> 00:04:47,619 ♪ ♪ 127 00:04:47,771 --> 00:04:49,513 - Think that's enough? - Yeah. 128 00:04:49,531 --> 00:04:51,606 - There you go. - See? That's quick, man. 129 00:04:51,700 --> 00:04:53,533 - It would really be a dick move 130 00:04:53,685 --> 00:04:55,460 Just to cut my piece off. 131 00:04:55,687 --> 00:04:58,630 So I stay and help cut him a piece as well. 132 00:04:58,857 --> 00:05:01,449 ♪ ♪ 133 00:05:01,543 --> 00:05:03,451 Which one you want? - I don't care. 134 00:05:03,545 --> 00:05:04,786 - They've both chosen to use 135 00:05:04,805 --> 00:05:06,471 About five inches of the spring. 136 00:05:06,698 --> 00:05:09,716 So they got a ton of steel there for their core material. 137 00:05:09,810 --> 00:05:11,310 - While this is heating up, 138 00:05:11,537 --> 00:05:14,871 I go over to the pantry and find my cladding. 139 00:05:14,964 --> 00:05:16,556 - Typically in the san mai competitions, 140 00:05:16,650 --> 00:05:19,726 We see smiths having awful time just getting that done 141 00:05:19,878 --> 00:05:22,321 With clean, pristine, bar stock. 142 00:05:22,472 --> 00:05:24,990 We're asking these guys to process and work down 143 00:05:25,217 --> 00:05:28,327 A two-inch diameter piece of round spring 144 00:05:28,554 --> 00:05:31,237 Before even cleaning it up, getting the cladding going, 145 00:05:31,332 --> 00:05:33,314 And getting to the starting point of a san mai billet. 146 00:05:33,334 --> 00:05:34,574 There's a lot of work 147 00:05:34,668 --> 00:05:36,668 In the first three hours of this competition. 148 00:05:36,820 --> 00:05:40,747 - Waiting on that steel to heat up drives me nuts, 149 00:05:40,841 --> 00:05:42,657 But if I don't let this piece of spring heat up 150 00:05:42,751 --> 00:05:44,843 As thoroughly as it needs to, 151 00:05:45,070 --> 00:05:47,829 Then I'm gonna end up getting cracks all the way through 152 00:05:47,923 --> 00:05:49,181 That piece, and I do not want that. 153 00:05:49,408 --> 00:05:52,834 ♪ ♪ 154 00:05:52,928 --> 00:05:55,169 - Josh and I decide to work together. 155 00:05:55,263 --> 00:05:56,521 - It's a big, old piece of steel, man. 156 00:05:56,748 --> 00:05:58,081 - I know. 157 00:05:58,100 --> 00:06:01,434 Cutting into the spring is very slow, 158 00:06:01,528 --> 00:06:04,196 But being in the marine corps definitely helped give me 159 00:06:04,423 --> 00:06:08,592 Determination to do a task until it's done. 160 00:06:08,610 --> 00:06:10,443 Come on, come on. 161 00:06:10,537 --> 00:06:13,763 - So what does rob here need to do to speed up the process? 162 00:06:13,857 --> 00:06:15,374 - He needs to heat up his torch. 163 00:06:15,601 --> 00:06:18,543 Put more acetylene in and then more oxygen in. 164 00:06:18,695 --> 00:06:19,711 - Hammer. - Here you go. 165 00:06:19,938 --> 00:06:20,712 - All right. 166 00:06:20,939 --> 00:06:23,106 ♪ ♪ 167 00:06:23,125 --> 00:06:25,217 - Rob really needs to start speeding up. 168 00:06:25,368 --> 00:06:28,369 - And now it's time to cut my piece. 169 00:06:28,463 --> 00:06:31,205 - Almost through. - There we go. Boom. 170 00:06:31,299 --> 00:06:32,391 - There's no time to waste. 171 00:06:32,542 --> 00:06:34,134 It's got to get in that fire right away. 172 00:06:34,228 --> 00:06:36,061 It's a big piece of steel. It's got a bend on it. 173 00:06:36,288 --> 00:06:38,212 I can't forge something straight onto something round. 174 00:06:38,232 --> 00:06:41,474 And I need it to be flat and so it can have a good bond. 175 00:06:41,627 --> 00:06:43,810 - What's the ideal thickness of the core material 176 00:06:43,904 --> 00:06:45,386 Before you go ahead and clad? 177 00:06:45,480 --> 00:06:47,130 - You want to have the same dimension 178 00:06:47,223 --> 00:06:48,798 As the cladding steel you've got. 179 00:06:48,817 --> 00:06:50,300 It's really what you want 180 00:06:50,318 --> 00:06:52,059 With nice, clean, square sides, you know? 181 00:06:52,154 --> 00:06:53,745 That would make a perfect weld. 182 00:06:53,972 --> 00:06:56,248 ♪ ♪ 183 00:06:56,399 --> 00:06:58,491 - I've got the coil spring up to heat. 184 00:06:58,644 --> 00:07:00,977 Now, I get it over to the press trying to 185 00:07:00,996 --> 00:07:03,496 Flatten it out and straighten it out. 186 00:07:03,590 --> 00:07:05,573 - Clay's already got a hot piece of metal. 187 00:07:05,667 --> 00:07:07,150 - He's been in there for 20 minutes. 188 00:07:07,243 --> 00:07:08,593 Now he can just run away with it. 189 00:07:08,820 --> 00:07:10,929 - Yep, just work it down on the press really quickly. 190 00:07:11,080 --> 00:07:13,840 You can be extremely aggressive with this stuff. 191 00:07:13,992 --> 00:07:16,009 - Now, I'm welding these suckers together 192 00:07:16,103 --> 00:07:17,602 As quickly as I can, 193 00:07:17,829 --> 00:07:19,438 Because I know that clock is running down. 194 00:07:19,665 --> 00:07:20,755 ♪ ♪ 195 00:07:20,849 --> 00:07:23,257 - Bladesmiths, one hour has elapsed. 196 00:07:23,351 --> 00:07:26,686 You've got two hours remaining. 197 00:07:26,780 --> 00:07:29,781 - I had my piece of spring steel nice and flat. 198 00:07:29,933 --> 00:07:31,524 - Rob's finished doing his cleanup. 199 00:07:31,618 --> 00:07:33,118 Oh, I guess he's-- 200 00:07:33,345 --> 00:07:34,936 He's mid-welding together all his layers. 201 00:07:35,030 --> 00:07:38,272 - I get my san mai pieces welded. 202 00:07:38,366 --> 00:07:40,959 So at this point, I'm feeling awesome. 203 00:07:41,186 --> 00:07:43,353 ♪ ♪ 204 00:07:43,446 --> 00:07:45,021 - Now that it's up to temperature, 205 00:07:45,114 --> 00:07:48,282 I'm gonna go gently set my san mai forge weld. 206 00:07:48,376 --> 00:07:50,026 If this forge weld goes wrong, 207 00:07:50,119 --> 00:07:52,028 I have to start completely over with cutting 208 00:07:52,047 --> 00:07:54,121 A whole new piece of coil spring. 209 00:07:54,216 --> 00:07:56,199 I do not have time for that. 210 00:07:56,218 --> 00:07:57,867 - Looks like he's running out of a little bit of heat. 211 00:07:57,961 --> 00:08:00,370 - Yeah, one of the reasons I'm not crazy about 212 00:08:00,463 --> 00:08:02,722 Setting long forge welds on a press 213 00:08:02,816 --> 00:08:05,817 Is that bottom piece is just sitting on that billet, 214 00:08:05,969 --> 00:08:09,470 Sucking the heat out of that bottom piece of steel. 215 00:08:09,564 --> 00:08:12,807 - So at this point, I'm pretty confident my welds are good, 216 00:08:12,901 --> 00:08:15,235 But now I have to keep stretching it, 217 00:08:15,329 --> 00:08:16,886 Keep stretching it some more 218 00:08:16,980 --> 00:08:18,830 Getting to where I have a blade. 219 00:08:19,057 --> 00:08:21,333 ♪ ♪ 220 00:08:21,560 --> 00:08:24,485 - Joshua's, I think, ready to clad his steel. 221 00:08:24,579 --> 00:08:26,062 - Once I'm up to temperature, 222 00:08:26,081 --> 00:08:27,506 Now it's time to get over to the press, 223 00:08:27,657 --> 00:08:30,233 And I want to very gently set these welds. 224 00:08:30,252 --> 00:08:32,085 - Looking at joshua's steel from here, 225 00:08:32,237 --> 00:08:34,513 He's looking pretty consolidated. 226 00:08:34,664 --> 00:08:36,681 - By my second pass on each side, 227 00:08:36,908 --> 00:08:39,259 I'm pretty confident that it's that it's forge-welded good, 228 00:08:39,353 --> 00:08:41,594 And it's time to heat this thing up and stretching it out. 229 00:08:41,688 --> 00:08:44,414 Making some bread. 230 00:08:44,507 --> 00:08:47,083 - The pressure is on for just to shape. 231 00:08:47,176 --> 00:08:49,176 When I heard the tests that the judges were 232 00:08:49,271 --> 00:08:51,196 Gonna be performing today, I immediately thought, 233 00:08:51,423 --> 00:08:54,924 "don't waste time forging a big, complicated tip. 234 00:08:55,018 --> 00:08:57,944 "just do simple, easy, competition chopper 235 00:08:58,038 --> 00:08:59,929 With a straight edge and a little bit of a belly." 236 00:09:00,023 --> 00:09:01,706 - My least favorite thing on the planet, 237 00:09:01,933 --> 00:09:03,283 The straight-bladed, 238 00:09:03,435 --> 00:09:05,710 Clip-point, competition chopper. 239 00:09:05,937 --> 00:09:08,195 - That's your least favorite thing on the planet? 240 00:09:08,290 --> 00:09:09,622 - Least favorite knife on the planet 241 00:09:09,716 --> 00:09:10,940 That's been on this show. - You haven't been out much. 242 00:09:11,034 --> 00:09:14,444 - Yeah. - At this point, I am beat. 243 00:09:14,462 --> 00:09:17,222 - 16 to 18 is a massive piece of metal. 244 00:09:17,449 --> 00:09:18,798 - It's a big blade. 245 00:09:18,950 --> 00:09:20,725 - But one way or another, I'm turning in a blade. 246 00:09:20,952 --> 00:09:22,302 ♪ ♪ 247 00:09:22,396 --> 00:09:25,288 - Bladesmiths, you are halfway through this round. 248 00:09:25,381 --> 00:09:26,898 You've got 90 minutes remaining. 249 00:09:27,125 --> 00:09:28,567 ♪ ♪ 250 00:09:28,794 --> 00:09:29,550 - Now that I've got the forge weld set, 251 00:09:29,644 --> 00:09:30,810 I've got to make a knife. 252 00:09:30,962 --> 00:09:33,238 And I've got to make a supersized knife, 253 00:09:33,465 --> 00:09:35,073 Not just any knife. 254 00:09:35,224 --> 00:09:36,557 So I'm going for 255 00:09:36,651 --> 00:09:37,984 In my house what we call a choppy chop. 256 00:09:38,136 --> 00:09:40,136 It's just a big chopper. 257 00:09:40,155 --> 00:09:41,988 It's got a little bit of recurve to it 258 00:09:42,140 --> 00:09:44,398 And it'll be great for chopping anything, 259 00:09:44,492 --> 00:09:47,827 Wood, ice, and it'll be sharp. 260 00:09:47,921 --> 00:09:50,404 - You know, for starting 20 minutes behind everybody else, 261 00:09:50,498 --> 00:09:53,407 Rob's making good time now. 262 00:09:53,501 --> 00:09:56,761 - I'm feeling awesome, and now it's time to start normalizing. 263 00:09:56,988 --> 00:09:59,823 ♪ ♪ 264 00:09:59,841 --> 00:10:01,658 - I still have to shape my blade. 265 00:10:01,676 --> 00:10:05,419 I think I'm gonna lean more toward my signature drop point. 266 00:10:05,513 --> 00:10:06,679 I want to add a little bit 267 00:10:06,832 --> 00:10:09,182 Of a recurve to it for the ice chop. 268 00:10:09,276 --> 00:10:11,759 Just to give a more forward heft for when they swing, 269 00:10:11,853 --> 00:10:13,445 It'll bite in a little bette. 270 00:10:13,596 --> 00:10:15,355 - Eland's got a big hunk of metal. 271 00:10:15,507 --> 00:10:17,340 - Yeah. - Oh, yeah. 272 00:10:17,359 --> 00:10:20,285 - So after lugging around this giant, honking piece of stee, 273 00:10:20,512 --> 00:10:23,029 My arms are tired. I'm exhausted. 274 00:10:23,181 --> 00:10:25,290 - Eland starting the work, his metal cold 275 00:10:25,517 --> 00:10:27,867 Losing all the color. - He keeps doing that. 276 00:10:27,961 --> 00:10:31,278 - Well, working the materials colder is never a good idea. 277 00:10:31,373 --> 00:10:33,022 I mean, you're gonna wind up 278 00:10:33,116 --> 00:10:35,634 Creating cracks and stress fractures. 279 00:10:35,785 --> 00:10:39,529 - I feel like I can't get it past that 16-inch mark 280 00:10:39,547 --> 00:10:41,306 And I am getting stressed. 281 00:10:41,533 --> 00:10:43,883 ♪ ♪ 282 00:10:43,977 --> 00:10:47,537 - Joshua has a beautiful rectangular shape to his blade. 283 00:10:47,555 --> 00:10:49,130 Now to start putting some form into that. 284 00:10:49,224 --> 00:10:50,798 - I want to make a machete. 285 00:10:50,817 --> 00:10:52,800 I think that's about the right size for a machete. 286 00:10:52,819 --> 00:10:54,727 I think it'll handle itself very well. 287 00:10:54,821 --> 00:10:56,729 Machetes are nostalgic to me, because I grew up 288 00:10:56,823 --> 00:10:59,473 In papua new guinea, and it was, like, an everyday tol 289 00:10:59,493 --> 00:11:01,734 That we had whenever we went around anywhere. 290 00:11:01,828 --> 00:11:04,721 You can't go through the jungle without a machete. 291 00:11:04,814 --> 00:11:08,667 - Bladesmiths, you have 45 minutes remaining. 292 00:11:08,894 --> 00:11:11,227 - Now it's time to quench this thing. 293 00:11:11,246 --> 00:11:12,912 I gotta do this right the first time, 294 00:11:13,006 --> 00:11:14,506 Because that clock is ticking. 295 00:11:14,733 --> 00:11:15,840 ♪ ♪ 296 00:11:15,992 --> 00:11:17,066 - Here we go. 297 00:11:17,085 --> 00:11:18,902 - That's a... - [groans] 298 00:11:18,920 --> 00:11:22,405 In the oil, like, all the way in the oil. 299 00:11:22,424 --> 00:11:23,497 - The minute I drop my blade in the oil, 300 00:11:23,591 --> 00:11:26,592 I thought, "oh, [bleep]. I'm going home." 301 00:11:26,687 --> 00:11:28,019 - Get it out of there. 302 00:11:28,246 --> 00:11:30,004 - Hopefully it didn't hit the bottom and bend. 303 00:11:30,098 --> 00:11:31,356 - This could be it for me. 304 00:11:31,583 --> 00:11:32,482 ♪ ♪ 305 00:11:36,363 --> 00:11:37,178 - I pull it out and to my surprise, 306 00:11:37,272 --> 00:11:39,088 It's pretty straight. 307 00:11:39,107 --> 00:11:42,683 For a second there, I thought this was over for me. 308 00:11:42,703 --> 00:11:44,035 I'm getting it over to the grinder, 309 00:11:44,187 --> 00:11:47,706 Cleaning it up as fast as I can. 310 00:11:47,933 --> 00:11:50,524 - Oh, no. - And I notice there's a crack 311 00:11:50,544 --> 00:11:53,269 All the way down the spine of this blade. 312 00:11:53,288 --> 00:11:55,696 Hoping that this crack doesn't run very deep 313 00:11:55,716 --> 00:11:57,941 And I can grind it out in a few minutes. 314 00:11:57,959 --> 00:12:01,461 ♪ ♪ 315 00:12:01,613 --> 00:12:02,870 - [screams] 316 00:12:02,889 --> 00:12:05,390 - That just seems like it went awesome. 317 00:12:05,541 --> 00:12:06,950 Right? [laughter] 318 00:12:06,968 --> 00:12:11,120 - The japanese believe that when you scream 319 00:12:11,139 --> 00:12:13,790 You're transferring your spirit into the blade 320 00:12:13,808 --> 00:12:18,294 And I transfer everything I have into that blade. 321 00:12:18,313 --> 00:12:20,129 ♪ ♪ 322 00:12:20,148 --> 00:12:22,056 What the [bleep]? 323 00:12:22,075 --> 00:12:23,483 - Holy smokes. 324 00:12:23,635 --> 00:12:26,077 - I have a supersized crack 325 00:12:26,229 --> 00:12:28,321 Going down the spine of the blade. 326 00:12:28,473 --> 00:12:29,914 - We've seen time and time again, 327 00:12:30,066 --> 00:12:32,141 In these san mai competitions especially 328 00:12:32,160 --> 00:12:34,978 With a high temperature quench that core material 329 00:12:34,996 --> 00:12:37,589 Just shearing and splitting straight down the middle. 330 00:12:37,740 --> 00:12:41,985 - I really am not sure if I'm gonna have time to fix it. 331 00:12:42,003 --> 00:12:45,246 ♪ ♪ 332 00:12:45,265 --> 00:12:48,324 - Eland just quenched, and it was hot. 333 00:12:48,343 --> 00:12:50,251 - Pulled out and checked. Everything looks great. 334 00:12:50,270 --> 00:12:51,752 Now I have to get to the grinder. 335 00:12:51,772 --> 00:12:55,164 I'm just hogging as much steel off as I can. 336 00:12:55,183 --> 00:12:56,682 Oh, come on. 337 00:12:56,835 --> 00:12:58,443 I have several spots show up, 338 00:12:58,670 --> 00:13:00,186 And it looks like it could be a crack. 339 00:13:00,338 --> 00:13:02,596 - It's once again the curse of the san mai. 340 00:13:02,616 --> 00:13:06,100 - Seriously. - A screaming hot quench, man. 341 00:13:06,119 --> 00:13:07,844 - I gotta get rid of that crack. 342 00:13:07,862 --> 00:13:11,197 If the cracks go all the way through I'm going home. 343 00:13:11,349 --> 00:13:12,515 Come on now. 344 00:13:12,534 --> 00:13:14,367 ♪ ♪ 345 00:13:14,519 --> 00:13:16,294 - In the oil. All right, guys, 346 00:13:16,445 --> 00:13:18,204 Four smiths, four quenched blades. 347 00:13:18,356 --> 00:13:20,114 - We got a nice, hard edge. 348 00:13:20,133 --> 00:13:23,876 Man, I am so relieved. I am so happy. 349 00:13:24,029 --> 00:13:25,044 I've gotta get to the grinder. 350 00:13:25,196 --> 00:13:26,787 I want to try to clean it up a little bit 351 00:13:26,807 --> 00:13:28,197 And just work to the last second. 352 00:13:28,216 --> 00:13:30,475 ♪ ♪ 353 00:13:30,626 --> 00:13:33,219 - Five, four, three, 354 00:13:33,371 --> 00:13:35,462 Two, one. 355 00:13:35,482 --> 00:13:36,981 Bladesmiths, turn off your machines. 356 00:13:37,133 --> 00:13:38,541 Put down your tools. 357 00:13:38,560 --> 00:13:39,984 The first round of this competition's over. 358 00:13:40,136 --> 00:13:42,469 - Good job, brother. 359 00:13:42,489 --> 00:13:44,564 - I wasn't able to fix that crack. 360 00:13:44,716 --> 00:13:46,324 At this point, I have to hope 361 00:13:46,475 --> 00:13:48,901 One of the other contestants has a worse blade than me. 362 00:13:48,995 --> 00:13:52,238 And I'm not very confident that I'll be advancing 363 00:13:52,390 --> 00:13:54,223 With that crack on the spine. 364 00:13:54,242 --> 00:13:56,559 ♪ ♪ 365 00:13:56,578 --> 00:13:57,836 - All right, bladesmiths, 366 00:13:58,063 --> 00:13:59,395 The time's come for the first critique. 367 00:13:59,414 --> 00:14:01,731 Eland, you're up first. Please present your work. 368 00:14:01,749 --> 00:14:03,566 ♪ ♪ 369 00:14:03,585 --> 00:14:06,493 - So, eland, great work in shaping this blade, 370 00:14:06,513 --> 00:14:08,329 But I've got some issues with it, 371 00:14:08,348 --> 00:14:13,184 Mainly that it's got a crack that runs from the spine 372 00:14:13,336 --> 00:14:15,912 All the way to basically the tang. 373 00:14:15,930 --> 00:14:18,097 And the worst part is, it runs on both sides. 374 00:14:18,249 --> 00:14:19,432 You get into the second round, 375 00:14:19,584 --> 00:14:21,751 You've got to take mass off of this thing 376 00:14:21,769 --> 00:14:24,420 And figure out some way to close that blade up. 377 00:14:24,439 --> 00:14:25,846 ♪ ♪ 378 00:14:25,866 --> 00:14:27,757 - Clay, sir, how you feeling? - I'm ready. 379 00:14:27,775 --> 00:14:29,425 - All right, please present your work. 380 00:14:29,444 --> 00:14:31,870 ♪ ♪ 381 00:14:32,021 --> 00:14:34,372 - All right, clay, let's talk about your blade here. 382 00:14:34,523 --> 00:14:39,210 So first off, you have a very basic design of a chopper, 383 00:14:39,362 --> 00:14:43,882 But what gives me pause is that there is a crack on the spine. 384 00:14:44,033 --> 00:14:46,959 The saving grace of that is, there's none on your edge. 385 00:14:47,112 --> 00:14:49,445 So should you move forward, 386 00:14:49,464 --> 00:14:52,298 I hope you have a plan to fix this and bring out its beauty. 387 00:14:52,450 --> 00:14:54,133 - Thank you. 388 00:14:54,285 --> 00:14:55,785 - Joshua, it's your turn. Please present your work. 389 00:14:55,803 --> 00:14:58,137 ♪ ♪ 390 00:14:58,289 --> 00:15:01,140 - All right, joshua, now, your blade's a solid quarter inch. 391 00:15:01,292 --> 00:15:02,383 There's a slight warp to it, 392 00:15:02,402 --> 00:15:04,051 But it's well within grinder range. 393 00:15:04,070 --> 00:15:06,312 Biggest thing is, if you're getting into the second round, 394 00:15:06,464 --> 00:15:09,056 Is to maintain that san mai. 395 00:15:09,075 --> 00:15:11,392 Don't lose all of that cladding material. 396 00:15:11,411 --> 00:15:13,302 Your steel looks good. Nicely done. 397 00:15:13,321 --> 00:15:14,895 - Thank you, sir. 398 00:15:14,915 --> 00:15:16,973 - Last but not least, rob. Please present your work. 399 00:15:16,991 --> 00:15:19,308 ♪ ♪ 400 00:15:19,327 --> 00:15:21,310 - Well, rob, this is a cool-shaped knife. 401 00:15:21,329 --> 00:15:23,570 I love the profile of it. Bevels are looking good, 402 00:15:23,590 --> 00:15:26,240 But the big thing here is that there's a huge crack 403 00:15:26,259 --> 00:15:28,426 That runs down the spine of your blade 404 00:15:28,577 --> 00:15:30,094 Really, really wide. 405 00:15:30,246 --> 00:15:32,430 I wouldn't at this point call it a catastrophic failure. 406 00:15:32,581 --> 00:15:34,507 In a competition like this, you can come back from this 407 00:15:34,659 --> 00:15:35,841 With the right kind of repair. 408 00:15:35,994 --> 00:15:37,435 Great job on the set up for this knife. 409 00:15:37,586 --> 00:15:38,844 Looks really good, 410 00:15:38,997 --> 00:15:41,088 But this crack really needs to be dealt with. 411 00:15:41,107 --> 00:15:44,000 - Absolutely. 412 00:15:44,018 --> 00:15:45,610 - Well, gentlemen, there's never anything easy 413 00:15:45,761 --> 00:15:47,503 About coming into a "forged in fire" competition 414 00:15:47,522 --> 00:15:50,673 And this one was massive, but only three of you 415 00:15:50,692 --> 00:15:52,858 Can join us in the second round of this competition. 416 00:15:53,011 --> 00:15:54,844 Now, after discussion, the judges all agreed 417 00:15:54,862 --> 00:15:56,512 That the smith who will not be joining us is... 418 00:15:56,531 --> 00:16:00,107 ♪ ♪ 419 00:16:00,126 --> 00:16:01,442 Eland. 420 00:16:01,461 --> 00:16:02,535 Unfortunately your blade didn't make the cut 421 00:16:02,687 --> 00:16:04,128 And ben's gonna tell you why. 422 00:16:04,280 --> 00:16:06,113 - Eland, a lot of people had cracks in their blades today, 423 00:16:06,207 --> 00:16:07,465 But yours is the only one 424 00:16:07,616 --> 00:16:08,967 That went all the way from the spine to the edge. 425 00:16:09,118 --> 00:16:10,134 And that really is 426 00:16:10,286 --> 00:16:11,861 A catastrophic failure of a blade, 427 00:16:11,879 --> 00:16:14,864 And it's for that reason we're gonna let you go. 428 00:16:14,882 --> 00:16:16,549 - Well, eland, you fought hard. 429 00:16:16,701 --> 00:16:17,642 You gave us a blade that met parameters, 430 00:16:17,793 --> 00:16:19,552 But unfortunately, it's not enough 431 00:16:19,646 --> 00:16:20,886 To get you to the second round of this competition. 432 00:16:21,039 --> 00:16:22,388 At this point in time, I'm gonna have to ask you 433 00:16:22,540 --> 00:16:25,466 To please surrender your work and step off the forge floo. 434 00:16:25,485 --> 00:16:27,968 - My blade wasn't the only one to crack, 435 00:16:27,988 --> 00:16:29,821 But unfortunately, my crack went all the way through, 436 00:16:29,972 --> 00:16:31,972 And it was just the worst out of the three that showed up. 437 00:16:31,992 --> 00:16:36,385 But I still produced a blade within the three hours 438 00:16:36,404 --> 00:16:38,645 In the supersize challenge on top of that. 439 00:16:38,665 --> 00:16:40,556 I'm proud that I fought till the end. 440 00:16:40,575 --> 00:16:43,075 ♪ ♪ 441 00:16:43,228 --> 00:16:44,577 - Well, gentlemen, congratulations. 442 00:16:44,671 --> 00:16:46,229 The three of you are joining us in the second round 443 00:16:46,247 --> 00:16:47,839 Of the supersize competition where you're gonna 444 00:16:47,990 --> 00:16:49,915 Fix all those issues the judges brought up about your blades, 445 00:16:50,068 --> 00:16:51,250 As well as add handles to them 446 00:16:51,402 --> 00:16:53,236 Turning them into fully functioning weapons. 447 00:16:53,254 --> 00:16:54,828 Now, if you take a look over at the pantry, 448 00:16:54,848 --> 00:16:56,663 You notice that all of our handle material has been 449 00:16:56,683 --> 00:17:00,576 Wiped from its shelves aside from four very large logs. 450 00:17:00,595 --> 00:17:02,669 Those logs are all you can use for the handles. 451 00:17:02,764 --> 00:17:04,355 After this round is done, 452 00:17:04,507 --> 00:17:06,173 You guys are gonna hand your blades over to our judges, 453 00:17:06,192 --> 00:17:07,767 And they're gonna test for strength and durability 454 00:17:07,919 --> 00:17:09,435 In an ice block chop and then 455 00:17:09,529 --> 00:17:12,421 Check your edger tension in a dual punching bag slice. 456 00:17:12,440 --> 00:17:14,515 You have a lot of work to do in these two hours. 457 00:17:14,534 --> 00:17:17,426 So good luck. That time starts now. 458 00:17:17,445 --> 00:17:19,262 ♪ ♪ 459 00:17:19,280 --> 00:17:20,446 Here we go. 460 00:17:20,598 --> 00:17:21,931 We got a lot of work to do on these blades. 461 00:17:21,949 --> 00:17:23,432 - A lot. - They're heavy. 462 00:17:23,451 --> 00:17:26,026 There's two massive cracks. How do we fix those? 463 00:17:26,120 --> 00:17:28,771 - The best thing to do is get a big, open crack in the back 464 00:17:28,790 --> 00:17:30,548 And just fill that whole thing with mig weld, 465 00:17:30,699 --> 00:17:32,108 Making sure that that heat 466 00:17:32,126 --> 00:17:34,460 Doesn't travel all the way down to the edge. 467 00:17:34,612 --> 00:17:36,370 - So I have a two-hour round. 468 00:17:36,389 --> 00:17:38,631 I have to take this supersized log 469 00:17:38,783 --> 00:17:41,617 And turn this material into handle material, 470 00:17:41,636 --> 00:17:46,289 But the first thing I have to fix is the crack on the spine. 471 00:17:46,307 --> 00:17:48,715 So I start welding it in little increments 472 00:17:48,735 --> 00:17:51,310 So I don't overheat the steel completely. 473 00:17:51,462 --> 00:17:53,312 Once you take your temperature 474 00:17:53,464 --> 00:17:56,390 Above the tempering temperature, 475 00:17:56,484 --> 00:17:58,317 Your heat treat is ruined. 476 00:17:58,469 --> 00:17:59,802 - You know what's going to be interesting 477 00:17:59,821 --> 00:18:02,729 About supersized blades, it's really gonna be testd 478 00:18:02,749 --> 00:18:05,157 During an ice block chop. - Absolutely. 479 00:18:05,310 --> 00:18:07,810 - More mass, more vibrations, 480 00:18:07,829 --> 00:18:09,570 More impact to travel through the whole thing. 481 00:18:09,589 --> 00:18:12,590 So if you do not address the cracks early, 482 00:18:12,741 --> 00:18:14,166 It's gonna open up. 483 00:18:14,319 --> 00:18:16,577 - I successfully closed the gap. 484 00:18:16,671 --> 00:18:19,488 I welded it up as best I could, and we'll see what happens. 485 00:18:19,507 --> 00:18:22,325 ♪ ♪ 486 00:18:22,343 --> 00:18:23,826 - Going into round two 487 00:18:23,845 --> 00:18:25,828 I'm very fortunate that I don't have any cracks, 488 00:18:25,921 --> 00:18:27,346 So that saves me a lot of time. 489 00:18:27,498 --> 00:18:28,681 I can jump on the grinder right away 490 00:18:28,833 --> 00:18:30,182 And start working on my warp. 491 00:18:30,276 --> 00:18:32,759 - You know, I'm watching joshua grind, and it's just 492 00:18:32,779 --> 00:18:35,004 A really inefficient way to remove material. 493 00:18:35,022 --> 00:18:37,523 And joshua's got a lot of material he has to remove. 494 00:18:37,675 --> 00:18:39,283 - Now that I got the warp out, 495 00:18:39,435 --> 00:18:41,510 I'm gonna start grinding down the rest of the blade 496 00:18:41,529 --> 00:18:42,936 And putting in the distal taper into it 497 00:18:42,956 --> 00:18:45,181 To thin it out and lighten it up on the end. 498 00:18:45,199 --> 00:18:46,958 And then I'm gonna start bringing in the bevels. 499 00:18:48,795 --> 00:18:50,611 - The risk I run welding the crack 500 00:18:50,630 --> 00:18:53,189 Is the heat traveling to the cutting edge 501 00:18:53,207 --> 00:18:55,133 And softening the edge. 502 00:18:55,284 --> 00:18:57,209 I'm gonna avoid that the best I can 503 00:18:57,362 --> 00:19:00,138 By submerging the edge in a pail of water 504 00:19:00,289 --> 00:19:03,032 To try and block that heat from traveling to the cutting edge. 505 00:19:03,050 --> 00:19:04,642 ♪ ♪ 506 00:19:04,793 --> 00:19:07,812 - Adding the extreme heat, it's kind of dangerous, right? 507 00:19:07,963 --> 00:19:09,388 You make it brittle now. 508 00:19:09,482 --> 00:19:11,540 - Yeah, but if you just kept the edge in the water, 509 00:19:11,559 --> 00:19:13,392 The heat would only travel down so far. 510 00:19:13,544 --> 00:19:14,894 There'd be a gradient of heat. 511 00:19:15,046 --> 00:19:16,879 - So he's just using it as a heat sink. 512 00:19:16,898 --> 00:19:18,156 - Yeah. 513 00:19:18,307 --> 00:19:20,807 - The back of this blade looks like a stegosaurus, 514 00:19:20,827 --> 00:19:23,386 But I'm out of time, and I have to move on. 515 00:19:23,479 --> 00:19:24,996 I'm heading over to the grinder 516 00:19:25,147 --> 00:19:27,223 To try to remove some of the meat from this blade. 517 00:19:27,241 --> 00:19:31,744 ♪ ♪ 518 00:19:31,838 --> 00:19:34,821 - I've taken a lot of weight out of the knife, 519 00:19:34,841 --> 00:19:39,251 And I'm ready now to try and move on to my handle material. 520 00:19:39,345 --> 00:19:41,662 - I'm excited to see how these guys tackle these logs. 521 00:19:41,681 --> 00:19:43,906 - They've got the option to use the wedges 522 00:19:43,925 --> 00:19:46,425 And smash them into these logs, but the bandsaw seems to be 523 00:19:46,577 --> 00:19:48,077 The most efficient tool to get the job done. 524 00:19:48,095 --> 00:19:49,854 - Oh, yeah. 525 00:19:50,005 --> 00:19:52,748 - I start hammering on it as hard as I possibly can 526 00:19:52,767 --> 00:19:56,419 And I'm not having any luck splitting this log. 527 00:19:56,437 --> 00:19:58,587 ♪ ♪ 528 00:19:58,606 --> 00:19:59,922 [sighs] 529 00:19:59,941 --> 00:20:02,107 ♪ ♪ 530 00:20:02,260 --> 00:20:04,109 So I go over to the bandsaw, 531 00:20:04,262 --> 00:20:07,263 And I check how high the gate is 532 00:20:07,281 --> 00:20:10,023 So that I can actually see if I can get it in there. 533 00:20:10,043 --> 00:20:11,600 And sure enough I can. 534 00:20:11,619 --> 00:20:14,787 I cut out a huge sliver, 535 00:20:14,939 --> 00:20:16,363 And now I'm back in the game 536 00:20:16,382 --> 00:20:18,607 To where I can make knife scales now. 537 00:20:18,626 --> 00:20:21,368 ♪ ♪ 538 00:20:21,387 --> 00:20:23,888 - After I get the majority of the grinding done 539 00:20:24,039 --> 00:20:25,372 And it's time for me to start working on the handle, 540 00:20:25,391 --> 00:20:27,558 So probably, the easiest way to get some wood 541 00:20:27,785 --> 00:20:31,120 Off of that log is to grab a splitter. 542 00:20:31,138 --> 00:20:32,730 And it's just bouncing. 543 00:20:32,881 --> 00:20:35,066 I've got to figure something else out. 544 00:20:35,217 --> 00:20:36,901 There's such a short amount of time, 545 00:20:37,128 --> 00:20:39,311 So I think maybe I'm just gonna have to 546 00:20:39,405 --> 00:20:41,722 Sharpen the splitter up, make it more like an axe, 547 00:20:41,741 --> 00:20:42,798 And try again. 548 00:20:42,817 --> 00:20:46,302 ♪ ♪ 549 00:20:46,320 --> 00:20:49,247 - Joshua over here, managed to split that log, 550 00:20:49,398 --> 00:20:52,641 But now he's got a rough piece of wood that's still a wedg. 551 00:20:52,660 --> 00:20:55,661 - Yeah. If nobody's on the bandsaw, use the bandsaw. 552 00:20:55,813 --> 00:20:57,162 - Bladesmiths, you guys are now 553 00:20:57,315 --> 00:20:58,647 Halfway through the handle round. 554 00:20:58,666 --> 00:21:01,484 You only have one hour remaining before tests. 555 00:21:01,502 --> 00:21:02,909 ♪ ♪ 556 00:21:02,929 --> 00:21:04,169 - I head over to the drill press 557 00:21:04,322 --> 00:21:07,414 And try to drill my pinholes. 558 00:21:07,433 --> 00:21:08,432 - All right, see if clay's able to 559 00:21:08,584 --> 00:21:10,101 Get through that thick, old tang. 560 00:21:10,252 --> 00:21:11,418 [drill rattling] 561 00:21:11,437 --> 00:21:13,587 - Yeah, by that sound I'd say, "nope." 562 00:21:13,606 --> 00:21:16,849 - No, it's not going well for him. 563 00:21:17,001 --> 00:21:18,851 - In round one when I quenched, 564 00:21:18,945 --> 00:21:21,353 I dropped the whole blade in the quench tank. 565 00:21:21,506 --> 00:21:22,947 - That's a... - [groans] 566 00:21:23,098 --> 00:21:25,932 - So this entire knife is hardened, 567 00:21:25,952 --> 00:21:28,027 And hardened steel does not drill. 568 00:21:28,121 --> 00:21:29,695 [drill rattling] 569 00:21:29,789 --> 00:21:31,104 - Clay's having trouble getting through it right now 570 00:21:31,124 --> 00:21:32,181 With only an hour left on the clock. 571 00:21:32,199 --> 00:21:33,291 ♪ ♪ 572 00:21:33,442 --> 00:21:34,941 - [bleep]. 573 00:21:34,961 --> 00:21:36,869 If I can't get the holes drilled in my tang, 574 00:21:37,021 --> 00:21:38,704 I won't be able to put pins 575 00:21:38,856 --> 00:21:40,798 And establish a mechanical connection. 576 00:21:40,949 --> 00:21:41,966 And I'd be going home. 577 00:21:45,954 --> 00:21:47,454 I look at the clock, and I know 578 00:21:47,473 --> 00:21:49,548 I can't waste time trying to drill through this. 579 00:21:49,700 --> 00:21:51,458 So I'm getting a little wild. 580 00:21:51,477 --> 00:21:53,460 - Holy smokes. 581 00:21:53,554 --> 00:21:56,372 It's not often you see somebody cut their holes in the tang. 582 00:21:56,390 --> 00:21:58,390 - It beats the heck out of burning up drill bits thoug. 583 00:21:58,543 --> 00:21:59,725 - Yeah, that's true. - You know. 584 00:21:59,877 --> 00:22:01,210 - If I can't drill through it, 585 00:22:01,228 --> 00:22:03,879 I'm gonna burn these holes through with a torch. 586 00:22:03,898 --> 00:22:05,548 This is something I've never done before, 587 00:22:05,566 --> 00:22:07,550 But desperate times call for desperate measures. 588 00:22:07,568 --> 00:22:10,143 ♪ ♪ 589 00:22:10,163 --> 00:22:12,555 It went swimmingly. I want this one. 590 00:22:12,648 --> 00:22:14,832 Now, I have to get this log split 591 00:22:14,983 --> 00:22:16,225 And get some wood for this handle. 592 00:22:16,243 --> 00:22:19,578 ♪ ♪ 593 00:22:19,730 --> 00:22:21,230 - The handle construction 594 00:22:21,248 --> 00:22:22,823 I'm gonna be doing on this is a full tang. 595 00:22:22,842 --> 00:22:24,900 So I'll be putting scales of this wood on each side 596 00:22:24,919 --> 00:22:27,086 Of the tang and pinning it in and gluing it. 597 00:22:27,238 --> 00:22:28,737 So I got all six holes in, 598 00:22:28,756 --> 00:22:31,574 And now I need to glue this thing on. 599 00:22:31,592 --> 00:22:33,742 I'm using some fast, five-minute setting epoxy, 600 00:22:33,761 --> 00:22:35,260 But I don't have five minutes to waste. 601 00:22:35,413 --> 00:22:37,262 So I quickly put some clamps on it, 602 00:22:37,415 --> 00:22:38,505 And I go over to my grinder, 603 00:22:38,524 --> 00:22:40,082 And I start working on sharpening it. 604 00:22:40,101 --> 00:22:43,176 ♪ ♪ 605 00:22:43,270 --> 00:22:45,254 - I put the epoxy on, 606 00:22:45,272 --> 00:22:49,091 And now it's time to wait for the epoxy to cure. 607 00:22:49,110 --> 00:22:52,536 It is five-minute epoxy, but when you're rushing, 608 00:22:52,688 --> 00:22:54,597 Those five minutes seem like eternity. 609 00:22:54,615 --> 00:22:55,873 ♪ ♪ 610 00:22:56,024 --> 00:22:57,357 - [laughs] what's that? 611 00:22:57,377 --> 00:22:58,692 - I don't know if that's how this works. 612 00:22:58,711 --> 00:23:00,527 - Yeah, blowing on it doesn't help. 613 00:23:00,546 --> 00:23:03,122 - Makes me feel better. - All right. 614 00:23:03,274 --> 00:23:05,608 - My epoxy is now hardened, 615 00:23:05,626 --> 00:23:09,053 And I realize that I barely have any time left. 616 00:23:09,204 --> 00:23:11,705 I want to make sure that everything is nice and smooth, 617 00:23:11,724 --> 00:23:13,891 'cause if the blade injures the user, 618 00:23:14,042 --> 00:23:15,117 It's not a good tool. 619 00:23:15,136 --> 00:23:16,877 ♪ ♪ 620 00:23:16,896 --> 00:23:18,562 - Rob's sharpening his blade right now. 621 00:23:18,714 --> 00:23:19,563 - That's good. - Yeah. 622 00:23:19,715 --> 00:23:21,047 - He needs the time. 623 00:23:21,067 --> 00:23:23,125 - I've still got to shape this handle 624 00:23:23,144 --> 00:23:26,237 And do an acid etch, and there are minutes left. 625 00:23:26,388 --> 00:23:27,963 The pressure is on. 626 00:23:27,982 --> 00:23:34,578 ♪ ♪ 627 00:23:34,730 --> 00:23:37,322 - Five, four, three 628 00:23:37,475 --> 00:23:39,399 Two, one. 629 00:23:39,419 --> 00:23:40,976 Bladesmiths, turn off your machines. 630 00:23:40,995 --> 00:23:44,588 Put down your tools. This second round is over. 631 00:23:44,740 --> 00:23:46,665 - I'm nervous going into testing, 632 00:23:46,817 --> 00:23:49,668 Because my handle's not as comfortable as I would like, 633 00:23:49,820 --> 00:23:52,078 The finish isn't as nice as I would like, 634 00:23:52,098 --> 00:23:54,490 And I'm still worried about those cracks. 635 00:23:54,508 --> 00:23:57,083 But just that I was able to complete the challenge 636 00:23:57,103 --> 00:23:59,328 Is an accomplishment in and of itself. 637 00:23:59,346 --> 00:24:01,772 ♪ ♪ 638 00:24:01,924 --> 00:24:03,849 - All right, bladesmiths, welcome to the strength test: 639 00:24:04,001 --> 00:24:06,760 The hanging ice block chop. 640 00:24:06,779 --> 00:24:07,928 Clay, you're up first. You ready for this? 641 00:24:07,947 --> 00:24:09,838 - Eh. - All right. 642 00:24:09,857 --> 00:24:11,615 ♪ ♪ 643 00:24:11,767 --> 00:24:13,509 - I'm not sure how 644 00:24:13,527 --> 00:24:15,936 The crack in my spine is gonna handle this chop. 645 00:24:15,955 --> 00:24:19,014 Worst-case scenario, the spine blows apart. 646 00:24:19,033 --> 00:24:25,796 ♪ ♪ 647 00:24:45,226 --> 00:24:47,209 - All right, clay, well, first thing I realized 648 00:24:47,228 --> 00:24:48,802 When I pick up this blade, though, is its weight. 649 00:24:48,896 --> 00:24:51,989 It's very heavy, and it's just a little difficult to control. 650 00:24:52,140 --> 00:24:53,324 Your edge here picked up a roll, 651 00:24:53,475 --> 00:24:55,141 And looking at your spine, 652 00:24:55,161 --> 00:24:57,720 There's a little bit of issue I can see with the mig weld, 653 00:24:57,738 --> 00:24:59,388 Some gas bubbles in the mig weld, 654 00:24:59,481 --> 00:25:01,390 But it held up great. Nice job. 655 00:25:01,408 --> 00:25:02,816 - Thank you, sir. 656 00:25:02,835 --> 00:25:03,909 - All right, joshua, you're up next. 657 00:25:04,061 --> 00:25:05,561 You ready for this? - Yes, sir. 658 00:25:05,579 --> 00:25:07,563 ♪ ♪ 659 00:25:07,581 --> 00:25:09,006 I'm pretty confident in my blade, 660 00:25:09,233 --> 00:25:10,232 'cause I got a good forge weld on that. 661 00:25:10,251 --> 00:25:11,658 But I am concerned about 662 00:25:11,677 --> 00:25:13,736 The edge taking damage on that ice. 663 00:25:13,754 --> 00:25:20,518 ♪ ♪ 664 00:25:39,113 --> 00:25:41,613 - All right, joshua, your pattern is really cool. 665 00:25:41,766 --> 00:25:43,189 I can see it on both sides. 666 00:25:43,209 --> 00:25:47,878 Your blade took a slight ding, but that being said, 667 00:25:48,030 --> 00:25:50,272 Blade is still straight. Nice job. 668 00:25:50,291 --> 00:25:51,790 - Thank you, sir. 669 00:25:51,942 --> 00:25:52,941 - All right, rob, you're up, man. 670 00:25:52,960 --> 00:25:54,443 You ready? - Absolutely. 671 00:25:54,461 --> 00:25:56,461 ♪ ♪ 672 00:25:56,614 --> 00:25:59,372 Doing an ice block chop destroys blades. 673 00:25:59,392 --> 00:26:02,134 They explode, and we already know 674 00:26:02,286 --> 00:26:03,727 That I have a crack in my spine. 675 00:26:03,879 --> 00:26:06,063 And I am not feeling okay for this. 676 00:26:06,214 --> 00:26:07,623 It is gut-wrenching, 677 00:26:07,641 --> 00:26:09,625 And I don't know what's gonna happen. 678 00:26:09,643 --> 00:26:10,568 ♪ ♪ 679 00:26:14,465 --> 00:26:18,867 ♪ ♪ 680 00:26:37,171 --> 00:26:38,262 - All right, rob, you nailed 681 00:26:38,489 --> 00:26:39,822 The supersized aspect of this thing. 682 00:26:39,840 --> 00:26:41,265 It's big in every dimension. 683 00:26:41,492 --> 00:26:43,583 The handle is big, but it's not overly big. 684 00:26:43,677 --> 00:26:46,161 The edge looks perfect. 685 00:26:46,180 --> 00:26:47,830 In all, I think you did a good job. 686 00:26:47,848 --> 00:26:49,014 - Thank you, sir. 687 00:26:49,166 --> 00:26:53,110 ♪ ♪ 688 00:26:53,337 --> 00:26:54,928 - Bladesmiths, this is the sharpness test, 689 00:26:54,947 --> 00:26:57,931 The double punching bag slice. 690 00:26:57,950 --> 00:26:59,842 Clay, you're up first. You ready for this? 691 00:26:59,860 --> 00:27:02,194 - If you must. - We must. 692 00:27:02,346 --> 00:27:09,126 ♪ ♪ 693 00:27:29,982 --> 00:27:31,798 All right, clay, let's talk about your chop here. 694 00:27:31,817 --> 00:27:33,892 First up, it is a heavy blade, 695 00:27:33,986 --> 00:27:36,820 But because of the weight coupled with a sharp edge, 696 00:27:37,047 --> 00:27:39,657 It really adds to cutting into these bags. 697 00:27:39,808 --> 00:27:42,551 Overall, your weapon, it will cut. 698 00:27:42,569 --> 00:27:44,644 - Thank you, sir. 699 00:27:44,664 --> 00:27:46,054 - All right, joshua, your turn. You ready? 700 00:27:46,148 --> 00:27:47,906 - I'm ready, man. Let's do this. 701 00:27:48,058 --> 00:27:54,672 ♪ ♪ 702 00:28:16,603 --> 00:28:19,512 - All right, joshua, let's talk about your blade over here. 703 00:28:19,532 --> 00:28:22,366 Now, your edge, first cut hit the stitching over there, 704 00:28:22,517 --> 00:28:24,517 But the rest of the bag, it just obliterated it. 705 00:28:24,537 --> 00:28:27,204 It's a very sharp edge. It's got a nice balance to it, 706 00:28:27,355 --> 00:28:30,432 A good feel swinging it, and overall, it will cut. 707 00:28:30,451 --> 00:28:32,284 - Thank you, sir. 708 00:28:32,436 --> 00:28:33,693 - All right, rob, your turn, sir, you ready? 709 00:28:33,713 --> 00:28:35,620 - Yes, sir. - Let's do this. 710 00:28:35,773 --> 00:28:42,386 ♪ ♪ 711 00:29:00,722 --> 00:29:01,721 All right, rob, let's talk about 712 00:29:01,741 --> 00:29:03,890 Your behemoth of a blade here. 713 00:29:03,984 --> 00:29:05,133 Now, the edge is sharp. 714 00:29:05,152 --> 00:29:07,302 Packed with the weight of this blade, 715 00:29:07,321 --> 00:29:11,139 It cuts deep into the bags, and overall, it will cut. 716 00:29:11,158 --> 00:29:12,324 - Thank you, sir. 717 00:29:12,476 --> 00:29:15,753 ♪ ♪ 718 00:29:15,980 --> 00:29:17,403 - Now, gentlemen, in this competition 719 00:29:17,423 --> 00:29:19,331 You guys all stood up to the massive task 720 00:29:19,483 --> 00:29:22,593 Of turning giant springs into san mai blades. 721 00:29:22,820 --> 00:29:24,094 But as you know, only two of you can join us 722 00:29:24,246 --> 00:29:26,096 In the final round of this competition. 723 00:29:26,248 --> 00:29:28,340 And after a discussion, our judges all agreed 724 00:29:28,492 --> 00:29:30,342 That the bladesmith leaving the forge is... 725 00:29:30,494 --> 00:29:32,844 ♪ ♪ 726 00:29:32,997 --> 00:29:34,346 Clay. 727 00:29:34,498 --> 00:29:35,497 Unfortunately, your blade didn't make the cut 728 00:29:35,590 --> 00:29:36,774 And doug's gonna tell you why. 729 00:29:36,925 --> 00:29:38,108 - Clay, first up, I want to commend you 730 00:29:38,260 --> 00:29:39,684 For the work you did. You can show us 731 00:29:39,779 --> 00:29:41,336 That even if you have a crack, if you make it through 732 00:29:41,355 --> 00:29:42,838 There are ways of fixing it, 733 00:29:42,856 --> 00:29:44,856 And it performed very well in our test. 734 00:29:45,009 --> 00:29:46,766 But the end of the day, your blade took some damae 735 00:29:46,860 --> 00:29:48,193 And is the least refined. 736 00:29:48,345 --> 00:29:49,769 And that's the reason you're not moving forward. 737 00:29:49,789 --> 00:29:51,288 - I understand. 738 00:29:51,439 --> 00:29:53,123 - Now, clay, we want to say thank you for comig 739 00:29:53,350 --> 00:29:54,625 And fighting so hard, but unfortunately, 740 00:29:54,852 --> 00:29:55,867 At this time I'm gonna have to ask you 741 00:29:56,020 --> 00:29:57,294 To please step off the forge floor. 742 00:29:57,521 --> 00:29:59,630 - Thank you. Good luck, guys. - Thank you. 743 00:29:59,857 --> 00:30:01,540 - I agree with the judges' decision. 744 00:30:01,692 --> 00:30:03,950 All three blades held up to the test pretty well, 745 00:30:03,969 --> 00:30:05,377 But the other two smiths 746 00:30:05,529 --> 00:30:07,379 Were just much more refined than mine. 747 00:30:07,531 --> 00:30:10,032 Even though I'm not leaving the "forged in fire" champion, 748 00:30:10,050 --> 00:30:11,700 I think I've still proved 749 00:30:11,718 --> 00:30:14,052 That I'm not just some guy making knives in his garage. 750 00:30:14,204 --> 00:30:17,815 ♪ ♪ 751 00:30:17,966 --> 00:30:19,632 - Joshua, rob, gentlemen, congratulations. 752 00:30:19,652 --> 00:30:21,968 Your hard work has paid off, and you're both moving forward 753 00:30:21,987 --> 00:30:24,212 Into the final round of the supersized competition. 754 00:30:24,231 --> 00:30:25,881 You probably noticed that throughout this competition 755 00:30:25,899 --> 00:30:27,566 We had a little bit of a theme. 756 00:30:27,660 --> 00:30:30,719 There were two giant springs, we had two ice blocks, 757 00:30:30,812 --> 00:30:32,830 And there were two punching bags. 758 00:30:32,981 --> 00:30:34,739 Well, we're gonna keep that theme of twos going. 759 00:30:34,892 --> 00:30:37,242 You guys will have four days to build these.. 760 00:30:37,394 --> 00:30:40,245 ♪ ♪ 761 00:30:40,397 --> 00:30:43,823 A pair of elephant fighting swords. 762 00:30:43,917 --> 00:30:45,676 - Awesome. - [laughs] 763 00:30:45,903 --> 00:30:47,344 - The double elephant fighting swords, 764 00:30:47,495 --> 00:30:49,513 Or dhaab ngao, trace their origins 765 00:30:49,664 --> 00:30:51,998 Back to 18th-century lan na kingdom 766 00:30:52,092 --> 00:30:53,575 In modern-day thailand. 767 00:30:53,594 --> 00:30:55,001 Used by mounted elephant warriors, 768 00:30:55,020 --> 00:30:56,836 These massive, heavy blades 769 00:30:56,856 --> 00:30:58,856 Featured a long handle to assist in counterbalance. 770 00:30:59,007 --> 00:31:00,916 Both blades measure around 30 inches 771 00:31:00,934 --> 00:31:02,508 And feature a flame-backed spine 772 00:31:02,528 --> 00:31:04,102 And an upswept tip. 773 00:31:04,254 --> 00:31:05,937 These swords were designed not only to attack 774 00:31:06,090 --> 00:31:08,607 Other mounted soldiers with lethal stabs and slashe, 775 00:31:08,759 --> 00:31:10,701 But the ridges and peaks along the spine 776 00:31:10,852 --> 00:31:13,095 Had the ability to trap an adversary's blade. 777 00:31:13,113 --> 00:31:14,763 Today these swords are still used 778 00:31:14,781 --> 00:31:17,099 In traditional thai martial arts. 779 00:31:17,192 --> 00:31:19,284 This is the largest pair of weapons 780 00:31:19,436 --> 00:31:21,378 We have ever asked smiths to go home and make. 781 00:31:21,529 --> 00:31:22,546 But, gentlemen, they need to fall within 782 00:31:22,697 --> 00:31:24,364 These followed parameters. 783 00:31:24,383 --> 00:31:27,609 Your blade length needs to be within 27 and 29 inches. 784 00:31:27,702 --> 00:31:29,961 You need to have an upswept tip, 785 00:31:30,114 --> 00:31:31,947 Three flames on the spine of each of your blades. 786 00:31:32,040 --> 00:31:33,706 Now, going down to the handle. 787 00:31:33,726 --> 00:31:37,561 It need to be ovoid in shape and between 17 and 19 inches. 788 00:31:37,712 --> 00:31:38,878 Now, guys, these are large blades, 789 00:31:38,898 --> 00:31:41,139 But that does not mean they should be heavy. 790 00:31:41,291 --> 00:31:44,568 Each one of these blades cannot exceed four pounds. 791 00:31:44,719 --> 00:31:46,719 - I have to make two elephant swords. 792 00:31:46,739 --> 00:31:48,647 Not one. I have to make two. 793 00:31:48,741 --> 00:31:50,632 Unbelievable. 794 00:31:50,651 --> 00:31:52,968 - Now, guys, you've got a ton of work ahead of you, 795 00:31:52,986 --> 00:31:54,302 But next time you enter this forge, 796 00:31:54,321 --> 00:31:55,470 One of you will be leaving with 797 00:31:55,489 --> 00:31:56,805 The title of "forged in fire" champion 798 00:31:56,898 --> 00:31:58,248 And getting a check for $10,000, 799 00:31:58,400 --> 00:31:59,583 So good luck. 800 00:31:59,734 --> 00:32:01,660 We will see you both in four days. 801 00:32:01,754 --> 00:32:02,827 - Let's do this. 802 00:32:02,980 --> 00:32:04,737 ♪ ♪ 803 00:32:04,757 --> 00:32:07,407 - Back here in my home forge in flagstaff, arizona. 804 00:32:07,426 --> 00:32:09,985 I've decided I wanted to make damascus for these blades, 805 00:32:10,003 --> 00:32:11,244 Something that stands out a little bit 806 00:32:11,263 --> 00:32:12,596 Against my competitor. 807 00:32:12,747 --> 00:32:14,489 All right, I'm gonna be using the 5160 808 00:32:14,508 --> 00:32:16,841 And some 15n20. 809 00:32:16,994 --> 00:32:18,602 I'm pretty comfortable making the sword. 810 00:32:18,829 --> 00:32:20,270 It's the time constraints that I have 811 00:32:20,422 --> 00:32:22,330 For making two of them in four days 812 00:32:22,424 --> 00:32:24,166 That's gonna be the tricky part. 813 00:32:24,259 --> 00:32:26,518 All right. I've only got one forge, 814 00:32:26,670 --> 00:32:28,445 So I want to get both of those billets in there if I can 815 00:32:28,596 --> 00:32:30,781 So I can rotate the billets back and forth 816 00:32:30,932 --> 00:32:32,598 And keep this process going along. 817 00:32:32,618 --> 00:32:34,676 So far, looking good. 818 00:32:34,769 --> 00:32:36,678 End of day one, I got a lot done, 819 00:32:36,697 --> 00:32:38,288 Was able to get about 90% 820 00:32:38,515 --> 00:32:39,698 Of the blades forged out this first day. 821 00:32:39,792 --> 00:32:41,441 So feeling good. 822 00:32:41,460 --> 00:32:43,443 I'm exhausted, but I'm ready to rock and roll tomorrow. 823 00:32:43,537 --> 00:32:45,870 Coming along. Whoo-hoo. 824 00:32:46,023 --> 00:32:48,114 ♪ ♪ 825 00:32:48,208 --> 00:32:52,043 - Day one, we're back in my home forge in north carolina. 826 00:32:52,137 --> 00:32:57,474 My goal is to make a 150-layer damascus billet. 827 00:32:57,625 --> 00:33:01,219 It's a lot of steel. It's enough for two sword. 828 00:33:01,371 --> 00:33:04,706 I'm using one big billet so that I can accomplish 829 00:33:04,725 --> 00:33:06,149 Both swords from one billet 830 00:33:06,376 --> 00:33:08,710 Rather than starting with two billets. 831 00:33:08,729 --> 00:33:11,229 So hopefully, it will go faster. 832 00:33:11,381 --> 00:33:12,472 Cool. 833 00:33:12,491 --> 00:33:14,566 I just finished day one. 834 00:33:14,718 --> 00:33:19,571 I was able to make my 150-layer billet of damascus. 835 00:33:19,723 --> 00:33:21,832 I'm a little bit nervous. I definitely feel behind, 836 00:33:22,059 --> 00:33:23,575 But I definitely feel it's gonna pay off. 837 00:33:23,727 --> 00:33:26,244 ♪ ♪ 838 00:33:26,396 --> 00:33:28,154 - Day two. 839 00:33:28,173 --> 00:33:30,899 So what's next is, I'm gonna start grinding in the profile 840 00:33:30,992 --> 00:33:32,676 So I can start making the shapes. 841 00:33:32,827 --> 00:33:35,846 So grinding these three flames into the top of these blades 842 00:33:36,073 --> 00:33:38,089 Is pretty tricky, and I can't mess this up, 843 00:33:38,242 --> 00:33:40,759 Because this is attached to this entire sword. 844 00:33:40,853 --> 00:33:43,411 I want to make sure that these flames look really nice, 845 00:33:43,430 --> 00:33:45,930 Because every little detail counts. 846 00:33:46,083 --> 00:33:48,525 And if rob does better than me or if I grind one too short, 847 00:33:48,752 --> 00:33:51,586 I could really mess myself up. I like it. 848 00:33:51,605 --> 00:33:53,846 So I've got the profile shaped out. 849 00:33:53,866 --> 00:33:56,091 I've to the flames all nice, so now it's time for me 850 00:33:56,109 --> 00:33:57,259 To get this thing heat-treated, 851 00:33:57,277 --> 00:33:58,443 'cause my time is ticking. 852 00:33:58,595 --> 00:34:04,099 ♪ ♪ 853 00:34:04,192 --> 00:34:07,435 Oh, yeah. Straight as an arrow. 854 00:34:07,454 --> 00:34:09,120 Wow. 855 00:34:09,273 --> 00:34:10,605 ♪ ♪ 856 00:34:10,624 --> 00:34:12,198 - It's the morning of day two. 857 00:34:12,217 --> 00:34:16,053 My plan for today is, I'm gonna forge out both blades 858 00:34:16,280 --> 00:34:17,888 And hopefully get them heat-treated. 859 00:34:18,039 --> 00:34:19,281 Getting there. 860 00:34:19,299 --> 00:34:20,891 I've never done anything this big, 861 00:34:21,042 --> 00:34:23,468 But I'm moving pretty quickly, very efficiently. 862 00:34:23,620 --> 00:34:27,713 So I can start building up my heat-treating oven. 863 00:34:27,733 --> 00:34:30,141 Unfortunately, I'm gonna have to modify this a little bit 864 00:34:30,235 --> 00:34:32,903 To get the swords in here, but it's gonna have to do. 865 00:34:33,054 --> 00:34:34,738 Because of the size of these blades 866 00:34:34,965 --> 00:34:37,557 Being able to heat these blades up evenly 867 00:34:37,576 --> 00:34:39,651 Is very challenging. 868 00:34:39,803 --> 00:34:40,819 There's one. 869 00:34:40,971 --> 00:34:43,321 ♪ ♪ 870 00:34:43,473 --> 00:34:44,823 There's two. 871 00:34:44,917 --> 00:34:48,326 There were no cracks, warps, nothing crazy like that, 872 00:34:48,478 --> 00:34:51,088 But my biggest concern throughout the entire 873 00:34:51,239 --> 00:34:53,406 Home forge challenge was my heat-treating. 874 00:34:53,425 --> 00:34:56,334 You know, my heat-treating oven was not up to par 875 00:34:56,486 --> 00:34:58,670 For handling that type of heat treatment. 876 00:34:58,764 --> 00:35:01,005 I really just hope that they're strong enough. 877 00:35:01,158 --> 00:35:04,843 ♪ ♪ 878 00:35:04,937 --> 00:35:06,436 - Day four. 879 00:35:06,663 --> 00:35:07,829 Yesterday I got started on the handle. 880 00:35:07,848 --> 00:35:09,422 So now it's time to do the glue up. 881 00:35:09,516 --> 00:35:10,774 I've got so many holes. 882 00:35:11,001 --> 00:35:12,592 I'm really concerned about making sure that 883 00:35:12,686 --> 00:35:13,777 All the pins fit in there 884 00:35:13,928 --> 00:35:16,020 And everything hooks up together nicely. 885 00:35:16,115 --> 00:35:17,763 That's not good. 886 00:35:17,783 --> 00:35:18,782 I'm gluing the first piece on, 887 00:35:18,933 --> 00:35:20,859 And the pins just aren't going in. 888 00:35:21,011 --> 00:35:22,861 Time is ticking, and I've got a lot to do. 889 00:35:22,955 --> 00:35:25,196 We just had ourselves a little catastrophe, folks. 890 00:35:25,349 --> 00:35:25,455 ♪ ♪ 891 00:35:29,369 --> 00:35:30,685 And I realize that I put it on the wrong side. 892 00:35:30,704 --> 00:35:32,187 So I've got to try again. 893 00:35:32,280 --> 00:35:33,855 I'm glad I caught that. Yeah. 894 00:35:33,874 --> 00:35:36,282 Okay, saved it. [laughs] 895 00:35:36,376 --> 00:35:37,859 Now I've got to hurry up. 896 00:35:37,878 --> 00:35:40,953 I named my swords chaos and tranquility 897 00:35:41,047 --> 00:35:43,807 Just because I used two different types of walnut. 898 00:35:44,034 --> 00:35:46,050 And it was sort of a yin and a yang feel for me. 899 00:35:46,145 --> 00:35:47,793 All glued up. 900 00:35:47,888 --> 00:35:51,797 Rob, I hope you did well, buddy, because it's game time. 901 00:35:51,817 --> 00:35:53,558 Whoo. 902 00:35:53,652 --> 00:35:55,226 ♪ ♪ 903 00:35:55,320 --> 00:35:56,378 - Day four. 904 00:35:56,471 --> 00:35:57,879 My overall plan for today 905 00:35:57,972 --> 00:36:00,565 Is to finish the handles, 906 00:36:00,717 --> 00:36:02,884 Get them glued up, basically sharpened up, 907 00:36:02,903 --> 00:36:04,977 Ready to test. 908 00:36:04,997 --> 00:36:06,646 Nice and smooth. 909 00:36:06,740 --> 00:36:10,167 At first I was a little worried about what I had to do 910 00:36:10,394 --> 00:36:12,394 At this supersized challenge, but ultimately, 911 00:36:12,487 --> 00:36:13,895 I feel really good about it. 912 00:36:13,988 --> 00:36:15,413 They feel good in the hand. 913 00:36:15,565 --> 00:36:17,340 I met all the parameters. 914 00:36:17,567 --> 00:36:20,251 Both my swords are light and fast, and they're sharp. 915 00:36:20,345 --> 00:36:26,925 ♪ ♪ 916 00:36:27,019 --> 00:36:29,260 - Joshua, rob, gentlemen, welcome back to the forge. 917 00:36:29,413 --> 00:36:30,836 We gave you four days at your home forges 918 00:36:30,856 --> 00:36:33,172 To work on the largest pair of weapons 919 00:36:33,192 --> 00:36:35,525 We've ever asked smiths to make in this final round. 920 00:36:35,752 --> 00:36:37,527 Guys, I've got to say, they look amazing. 921 00:36:37,754 --> 00:36:39,029 But before we put them to the test 922 00:36:39,256 --> 00:36:40,438 To find out which one of you is coming out on top 923 00:36:40,532 --> 00:36:41,847 Of this competition, I want to hear about them. 924 00:36:41,942 --> 00:36:42,941 So, rob, how'd you build yours? 925 00:36:43,035 --> 00:36:45,035 ♪ ♪ 926 00:36:45,186 --> 00:36:49,447 - I made a 150-layer damascu, and then I used purple heart 927 00:36:49,599 --> 00:36:51,524 And osage orange for the handle material 928 00:36:51,543 --> 00:36:53,693 - Awesome, man. Joshua, how about you? 929 00:36:53,787 --> 00:36:58,106 - So I'd like you to meet chaos and tranquility over here 930 00:36:58,199 --> 00:37:01,960 Made of 5160 and 15n20 steel 931 00:37:02,054 --> 00:37:04,221 With a low-layered, bold-patterned damascus, 932 00:37:04,448 --> 00:37:07,039 Walnut handles, and some copper damascus 933 00:37:07,133 --> 00:37:08,725 For the bolsters. 934 00:37:08,952 --> 00:37:10,710 - Outstanding. Gentlemen, after today 935 00:37:10,729 --> 00:37:12,287 One of you is gonna earn the title 936 00:37:12,305 --> 00:37:14,305 Of "forged in fire" champion, get a check for $10,000. 937 00:37:14,399 --> 00:37:16,140 Because this is the supersized competition, 938 00:37:16,235 --> 00:37:17,383 We're gonna put your blades through a series 939 00:37:17,477 --> 00:37:18,568 Of supersized tests. 940 00:37:18,795 --> 00:37:21,963 And up first, the keal test with doug. 941 00:37:22,056 --> 00:37:25,817 - Bladesmiths, welcome to the keal test. 942 00:37:25,969 --> 00:37:27,302 Rob, you're up first. You ready for this? 943 00:37:27,395 --> 00:37:30,229 - Absolutely. Let's do it. 944 00:37:30,323 --> 00:37:32,807 At first sight these tests are definitely terrifying, 945 00:37:32,900 --> 00:37:34,325 Because I know that my blades 946 00:37:34,419 --> 00:37:37,254 Had some struggles in the heat-treating area. 947 00:37:37,481 --> 00:37:39,814 One dummy's bad enough, but to see two 948 00:37:39,907 --> 00:37:42,074 Is not an exciting thing. 949 00:37:42,094 --> 00:37:43,668 I'm so nervous. 950 00:37:43,762 --> 00:37:45,428 ♪ ♪ 951 00:37:49,175 --> 00:37:52,936 ♪ ♪ 952 00:38:38,150 --> 00:38:39,541 - All right, rob, let's talk about 953 00:38:39,559 --> 00:38:41,042 Your elephant fighting swords here. 954 00:38:41,061 --> 00:38:43,394 First up, the damascus path 955 00:38:43,547 --> 00:38:45,971 That you have here are stunning, 956 00:38:45,991 --> 00:38:48,641 But we have a problem. 957 00:38:48,660 --> 00:38:52,570 During the test both blades took a very significant bend. 958 00:38:52,722 --> 00:38:53,830 As you can see here, 959 00:38:54,057 --> 00:38:56,057 They're kind of off-center, not centered. 960 00:38:56,076 --> 00:38:57,834 And judging by how extreme these are 961 00:38:58,061 --> 00:39:00,319 It looks like a major heat-treat issue 962 00:39:00,339 --> 00:39:01,729 With both your blades. 963 00:39:01,748 --> 00:39:03,231 With every strike 964 00:39:03,249 --> 00:39:05,567 They will continue to bend more and more, 965 00:39:05,585 --> 00:39:09,087 So unfortunately, I would not feel safe testing them further. 966 00:39:09,239 --> 00:39:12,574 ♪ ♪ 967 00:39:12,592 --> 00:39:13,683 - Now, rob, both your blades 968 00:39:13,835 --> 00:39:14,851 Did make it through our keal test, 969 00:39:15,078 --> 00:39:16,853 But in the midst of that test they both took 970 00:39:17,080 --> 00:39:19,505 Very serious bends down near the handle. 971 00:39:19,524 --> 00:39:21,858 Our judges did decide to issue a vote of no confidence, 972 00:39:22,085 --> 00:39:23,751 And we cannot continue testing your blades. 973 00:39:23,770 --> 00:39:25,362 But you're not out of the fight yet. 974 00:39:25,513 --> 00:39:27,179 Joshua, in order to take home the title of 975 00:39:27,273 --> 00:39:28,923 "forged in the fire" champion and get a check for 10 grand, 976 00:39:28,942 --> 00:39:31,275 Your blades will have to make it through our keal test 977 00:39:31,428 --> 00:39:33,761 With no disqualifying issues. Are you ready? 978 00:39:33,780 --> 00:39:35,947 - I am so ready. Let's do this. 979 00:39:36,099 --> 00:39:37,265 ♪ ♪ 980 00:39:37,283 --> 00:39:39,117 I have some chaos and some tranquility 981 00:39:39,269 --> 00:39:40,710 Going on in my body. 982 00:39:40,862 --> 00:39:42,528 I mean, rob, obviously has a bend, 983 00:39:42,622 --> 00:39:44,455 But mine might break. 984 00:39:44,608 --> 00:39:51,388 ♪ ♪ 985 00:40:31,579 --> 00:40:32,578 - All right, joshua, let's talk about 986 00:40:32,672 --> 00:40:34,246 Your elephant swords here. 987 00:40:34,266 --> 00:40:35,765 These blades are nicely done. 988 00:40:35,917 --> 00:40:37,659 I don't see any damage to your blades. 989 00:40:37,677 --> 00:40:39,102 They're nice and tight and straight. 990 00:40:39,253 --> 00:40:42,180 Over all, your weapons will keal. 991 00:40:42,332 --> 00:40:44,757 - Thank you. 992 00:40:44,776 --> 00:40:46,017 - Well, joshua, congratulations. 993 00:40:46,169 --> 00:40:47,259 Your blades made it through the keal test 994 00:40:47,279 --> 00:40:48,686 Completely unscathed. 995 00:40:48,838 --> 00:40:49,946 Now, rob, we want to say thank you for coming out 996 00:40:50,097 --> 00:40:51,114 And trying so hard in this competition, 997 00:40:51,265 --> 00:40:52,598 But your time in the forge has ended. 998 00:40:52,692 --> 00:40:53,858 I'm gonna have to ask you 999 00:40:54,010 --> 00:40:55,526 To please step off the forge floor. 1000 00:40:55,679 --> 00:40:56,861 - Thank you. Appreciate it. - Thank you so much. 1001 00:40:57,013 --> 00:41:00,364 - I absolutely know what was wrong with the blades. 1002 00:41:00,517 --> 00:41:02,441 I didn't have a heat-treating oven big enough. 1003 00:41:02,461 --> 00:41:04,610 I had a feeling that that was gonna be a weak spo, 1004 00:41:04,629 --> 00:41:06,521 And it was dead-on. 1005 00:41:06,539 --> 00:41:08,781 I absolutely enjoyed the build. 1006 00:41:08,875 --> 00:41:12,376 This definitely pushed my-- my boundaries, and that's good, 1007 00:41:12,529 --> 00:41:14,045 'cause what doesn't kill you makes you stronger. 1008 00:41:14,197 --> 00:41:17,456 ♪ ♪ 1009 00:41:17,476 --> 00:41:20,051 - Well, joshua, you are the new "forged in fire" champion, 1010 00:41:20,145 --> 00:41:21,978 And you're gonna be receiving a check for $10,000. 1011 00:41:22,205 --> 00:41:24,388 Congratulations. - Thank you so much, guys. 1012 00:41:24,541 --> 00:41:25,982 It feels amazing. 1013 00:41:26,133 --> 00:41:27,484 It's very surreal. I can't believe it. 1014 00:41:27,711 --> 00:41:29,152 - You got plans for the money? - [laughs] 1015 00:41:29,379 --> 00:41:31,154 It's gonna go back to my shop. - Right on. 1016 00:41:31,305 --> 00:41:33,564 - This was a huge personal journey for me, 1017 00:41:33,717 --> 00:41:35,883 But as a full-time bladesmith and artist 1018 00:41:35,902 --> 00:41:38,310 It pushed my creativity, ingenuity, 1019 00:41:38,404 --> 00:41:40,404 And it was incredible. 1020 00:41:40,557 --> 00:41:41,831 I'm joshua meyer, 1021 00:41:41,983 --> 00:41:43,074 And I'm the "forged in fire" champion. 1022 00:41:43,226 --> 00:41:49,797 ♪ ♪