All language subtitles for Forged.in.Fire.S09E02.720p.WEB.h264-BAE

- My name is dan greene.

I'm 25 years old.

I've been making knives
about three years now.

From a very early age,
I always liked tattoos.

Actually gave
myself this sleeve.

In some ways, I would say
it's a little better

Than another artist
to give you tattoos.

Just... Knuckles
hurt quite a bit.

- My name is sean meadows.

I am 20 years old,

And I am a full-time
bladesmith and woodworker.

My mother has
lent me 1/2 of her garage

To set my entire workshop up in.

As much as I love
being able to work

In my mom's garage,

Winning $10,000 would finally

Be the ticket that I need
to move out into my own shop.

- My name is jd bostick.

First learned to bladesmith

About 12 years ago.

I have two kids.

Their names are kaya and miko.

They inspired me
to get on "forged in fire."

They said, "just don't
get out in the first round,"

So here's hoping.

- I'm ron berkland.
I'm 50 years old.

I've been bladesmithing
for three years.

I was in the military

Where I spent 18 years
in the national guard.

And I spent
four years active duty,

So I did 22 years complete.

My experiences in the military

Helped me feel like I can
accomplish anything.

- Bladesmiths,
welcome to the forge.

The four of you have
been chosen to take part

In an intense
bladesmithing competition

That'll all culminate
with one of you leaving here

With the title
of "forged in fire" champion,

And a check for $10,000.

- What am I going
to be expected to do?

A canister, canoe damascus.

I am super excited
but very nervous.

- Bladesmiths,
you've all got a cloth

On the anvils in front of you.

Go ahead
and take that off for me.

Bladesmiths,
what you're staring at there

Is a bar of
w1 high-carbon steel.

All we're asking you to do

Is make a signature blade

In your signature style
using mono steel.

- What's the catch?

It's "forged in fire."
there's always a catch.

- Now guys, just make sure

That those blades fall within
these following parameters.

Your blade length
measured from tip

To where the cutting edge ends
in a straight line

Needs to be between
11 and 13 inches.

Each of you
will have to turn in a blade

That has a recurved edge.

Now as far as designing
for the test goes,

I'm going to leave you
in the dark there, guys.

You're not going to know

How we're going
to test for strength

Or test for your edge retention

Until we get there.

For this first
round of competition,

There are three
hours on the clock.

All right, gentlemen, good luck,

Stay sharp, your time starts...

- What the hell is going on?

- Bladesmiths, as you can see,
we're experiencing

A bit of a blackout
in the forge today.

Each of you
has a lamp behind you.

Go ahead and light
then hang them up for me.

Word is that the electrician
will not be available

To turn the power back on
until after the second round.

There's no power
to the power tools.

The only things you have
are the forges and hand tools.

You didn't think you're gonna
get off that easy, did you?

- Nah.

No power tools, no big blu,

No drill press.

It's going to be challenging,

But that's the fun part of it.

- At the end of each round,

I will ask you
to present your work

To our panel of expert judges.

They are the ones
who'll be deciding

Which three of you
are leaving here empty-handed,

And who's going
to be leaving here

With the title
of "forged in fire" champion,

And that check for $10,000.

Now, good luck, gentlemen,
because your time starts now.

Now I got to really
pay attention to my watch

'cause with the power
going down,

The clock's out too.

These guys have
no clock to reference

How long they've got left.

We've never done
a no electricity competition.

- Yeah, I mean,
the only time we've ever done

Something that was even close
is when we were doing

A coal forge situation.
- Right.

- And even then,
they usually had

Electric angle grinders
and things like that.

- I am very concerned
about overexertion

Going into this competition.

I'm gonna need to make sure

That I don't get off
to too hot of a start,

Or else I'm never going
to be able to finish.

- Learning how metal moves
under a hammer on an anvil

Are things that a lot
of smiths don't learn.

Most of the stock
that we start out with

Is already in a bar form.

- I learned all of my skills

From watching videos online.

Feeling like
I'm at a disadvantage,

But I'm still gonna try my best.

- I'm excited about
seeing this competition,

But we would have had
electricity, dave,

If you would remember
to pay the damn bill.

- I had used w1
for a few projects.

I have not moved this much w1

And moved it to this extreme,

So this is gonna be
a big challenge.

I want to stretch out the bar
to meet my blade requirement.

So that's my biggest focus.

- Just gotta get
a blade I can turn in.

W1, it's really hard to work

And we get a 1-inch round of it,

And we gotta draw this out...

Without power.

If steel gets too cold,

You can definitely develop
cracks in w1.

So, I gotta keep it hot
and keep it moving.

I'm hammering hot metal,
have a piece of slag hop off

And land
right on my index finger.

And I can immediately
feel it blistering.

Thank you.

- If any guy gets
an injury that keeps them

From being able to swing,
that can take him

Out of the competition
completely.

They couldn't go rely
on big blu or the presses.

- I just got
to push through the pain.

I can't waste any more time.

- Doing what these guys
are doing with hand tools

In three hours
is very, very abnormal.

- Very interesting.

Dan is kind of ambidextrous
right there.

He was just hammering
in one hand

And switched over
and used the other hand.

- I've taught myself
how to use both hands,

Left and right, forging.

I'm going to use it
as much as I can

In order not to tire
my right arm out.

Even though
I'm using both hands,

Man, it would be fantastic
to have a press right now,

'cause this is brutal.

- All right, bladesmiths,
you are 30 minutes in.

You have 2 hours
and 30 minutes left.

- Whoo-wee!

You're very welcome.

- You can start to see
sean's profile coming in now.

Just how is he going
to work in that recurve?

- The biggest issue
is that I'm not used to

Working with stock
that's this thick.

- We know what kind
of blades they're making,

I asked for a recurve.

But is there anything really

They can be doing
to get ahead of the game?

- With not
having the power tools,

They really need to use
every portion of that anvil.

- Exactly.
- Especially the horn

For that recurve.

That's what the horn
of the anvil is meant for.

- I got this thing looking good.

Now I can move forward.

I think I got it.

I have my blade length,

So now I can work on
the shape of my blade.

I don't know the tests,

But a recurve tells me
there's possibly a chop test.

And then I have to figure in
that it could be a stab test,

So I have to have
a decent tip on my blade.

- This is one of those
competitions that having

A knowledge of a lot
of different knife shapes

Would really pay off.

Because you can
start thinking, okay,

What shape is going to
allow me to move

The least amount of metal
in the quickest amount of time?

- It's getting there.

My wife is a big doug fan.

So I want to try to impress
doug with my blade.

- We have to have
a recurve in the blade.

Doing good.

If I don't give it enough belly,

It's not going to look
like a recurve.

I really want to hear doug
say that my knife's

"sexy."

- Jd is having some trouble
moving that steel.

- Seeing some of those
really deep curves in the blade

Get hung up in testing material.

- Having the blister
forming is tough.

I'm feeling the grip
already getting sore.

That bitch is heavy.

But you just have to keep going.

- I got my blade to length.
So now I can start shaping it.

I'll probably call the blade
shape that I'm going for

Some kind of a kukri.

Looks good.

- Dan's blade is one
of the nicer shapes

I've seen in a long time.

And he's doing it all by hand.

- I feel pretty good
about the shape.

But I just know I need
to get a move on the tang

'cause that's gonna be fairly
time-consuming to draw out.

- I'm gonna try
to get just a bit more length

And then get to driftin'.

- I've never drifted a hole.

Always drilling.
- Never?

- Never.
- I've done it like twice.

It's awful.

Normally,
you're just gonna drill

Right through the material,
and it's super easy.

But I don't
have power for a drill press,

So I have to finish up
these punches before quench,

Because as soon
as the quench happens,

The blade will be too hard
to punch pin holes.

But, luckily,
drifting these tang holes

Is surprisingly easy.

Hell yeah!

So I am riding high.

- Come on, baby!

I'm putting
in the bevels on my blade.

Trying to put in
the edge on this

Is gonna be very difficult

Without power tools
after it's tempered.

- Developing
the traditional skill sets

With just hammer and anvil
really allows you

To branch out
and do other things.

- I'm pretty confident I'm going

To accomplish this
in the time I have left.

- Ten, nine, eight...

Naw, I'm just kidding, guys.

You're halfway through.

You have 90 minutes left.

That's not funny.

- If you're up there it's funny.

It's not funny out here.

After I've got these
holes drifted through,

Next thing I know dan and sean,

They are already
putting a bevel on this thing.

, you guys are way ahead of me.

I realized I was falling
behind at this point.

So I've got to get a bevel
in this blade and fast.

But I've never filed
a bevel into a blade before.

So I'm making the choice

To go with my flattening hammer.

- This right now is gonna be
hard for these guys.

They gotta forge
those bevels all the way in.

You can't get a part
of the way and grind it down,

So you got to get
that drawn all the way down.

- The flattening hammer
works great

To beat a bevel into this thing.

I feel like I made up
a lot of ground

In the last 30 minutes

And the end is within sight.

- Feeling it, man.

I feel pretty good
about my bevels.

But now I'd have to punch holes.

I'm a little nervous.

I've actually
never done that before,

But we'll see how it goes.

- Those punches he's using

Are not made
to go through hot metal.

We have drifts in here
that are specifically made

To punch holes in steel.

As I'm trying to drift
this hole, the punch breaks.

So I'm feeling
a little bit frustrated.

But I've got to make it work,
so I grab another.

It breaks instantly.

- Oh no.

- Well, now,
dan needs to get another punch.

- So I grab a third punch.

And that one breaks as well.

So I'm just, you know,

Getting a little bit
frustrated with it.

- Dan's having a lot of trouble
trying to get those holes in.

- That punch is spreading out
as opposed to going through.

- If I'm not able
to punch these holes,

I would definitely be sent home.

I just don't know what to do.

- There's a blackout,
and there's no power tools.

So I'm trying to get
these holes punched by hand.

And these punches keep breaking.

If I'm not able
to punch these holes,

I could definitely
get eliminated.

But I'm not just gonna give up
or throw in the towel.

I'm... I'm gonna keep
smashing them in there

Till they're through.

Right on.

So I finally get
the punch through.

It's a little bit of relief,

But I've wasted too much time.

- Bladesmiths,
you guys have 30 minutes left

Before the first elimination.

- Time is running out.

I need to get this thing
in the quench tank,

And I'm freaking out.

It'll have to do.

If I get a warp in the blade,

I'm not gonna have
enough time to fix it.

- With just a bit
of time on the clock,

Quench the blade,
make sure it's straight,

And you can continue
to file a hard blade.

It's definitely gonna be
harder to move metal,

But you're not
gonna get anywhere

If you don't have
that blade quenched.

- There we go, three down.
Dan's gonna be the last to go.

Bladesmiths,
you have 15 minutes left.

- I'm running behind schedule.

We'll see.

I've wasted too much
time punching holes.

So I'm gonna take my chances

And skip normalizing
in order to save time.

The main thing I'm worried
about with cutting corners

With normalizing
is that there could be cracks.

- You have
two minutes remaining.

There we go.

All right,
all four blades are quenched.

Dan's in the oil.

- A little twist.

I do see a small twist
at the tip of the blade,

So I'm going to
try to straighten it out

With light taps.

There's definitely
a risk to doing that,

'cause now there
could be cracking as a result.

I hope this decision doesn't
have any major lash back.

- Five, four, three, two, one.

Bladesmiths,
put down your tools.

The first round of this
blackout competition's over.

- I'm very proud of the work
that I've done in three hours

Without having a press
or a power hammer.

But I'm most nervous in
the critique about something

I'm not able to see in the dark.

- Bladesmiths, congratulations.

You guys made it through
the first three hours

Of this blackout competition
with no electricity,

Solely manpower.

The time has come
for the first critique.

Dan, you're up first.
You ready?

- Absolutely.
- Please present your work.

- All right, dan.

You did a real fine job
moving that steel by hand.

You were just
chugging right along.

But you did rush the heat treat.

That concerns me.

But everything else, good job.

- Thank you.

- All right, sean, you're up.
You're ready?

- Yes, sir.
- Please present your work.

- All right, sean.

Got a nice profile
with your blade.

But your curvature
that you have here,

It's got to flow
a little bit more

So that it doesn't get hung up.

If you go to the second round,

You just got to smoothen
that out and refine it.

But overall, good job.
- Thank you, sir.

- Alright, jd, you ready?
- I am, sir.

- Please present your work.

- All right, so jd, good job.

The biggest concern I have
with your blade is the profile.

Right now,
you've got this large belly

Way at the front of this blade

That may affect the way it cuts.

Handle-wise, it's sticking up
above everything.

Kind of drives
everything back into the hand.

But the blade is straight.

Good job.

- Thank you, sir.

- Finally, we got ron.
You ready?

- Moving forward.

- Please present your work.

- All right, ron.

First up,
nice hammer strikes in there.

Now your recurve here,
you have a belly

That's prominent to where
I can't decide whether

I'm gonna cut with this
or cut with this belly.

If you move forward,
I'd like to see

Your recurve here
be much more subtle.

But overall, good job.

- Gentlemen, you guys
all brought forward blades

That met our parameters.

But, guys, in this competition,
only three of you

Can join us in the second round.

And although difficult,

Our judges
did make a common decision.

The bladesmith
leaving the forge is...

Jd, unfortunately, your blade
didn't make the cut,

And j.'s gonna tell you why.

- Jd, that was
a really tough challenge

And we had to pick
out little differences.

But the reprofiling
of your blade is going to have

More work for you
than your other smiths.

That's why
we're sending you home.

- I understand.
- Well, jd, you showed us

You're a talented smith,
but unfortunately

Your time in this
competition has ended.

I'm gonna have
to ask you to please

Step off the forge floor.

- Even though my kids said,

"just don't get
out in the first round,"

I know that my kids
will always be proud of me.

But when I get home,
I am definitely

Gonna remember
to pay my electric bill

So I never have to forge
in the dark again.

- All right, gentlemen,
congratulations.

The three of you are joining us

In the second round
of this competition

Where you're adding handles
to your blades,

Turning them into
fully functioning weapons.

But unfortunately, as you know,

The power is still out
in the forge.

So all the tools on the forge
floor are out of commission.

But, thankfully for you,

I was able to scrounge these up.

Gentlemen,
we've got some battery-powered

Drills and angle grinders
for you to use

During the second round.

- We get power
equipment now, yes.

Drills, grinders, yay!

That makes me happy.

- Now as far as testing goes,

You're still
going into that blind.

But I will tell you,
it's gonna be very difficult.

So work as hard as you
can during this entire round.

Gentlemen,
you only have two hours

On the clock
to complete your blades.

Good luck,
because that time starts now.

Seems like giving these guys
the battery powered tools

Makes things
a little bit easier for them.

- There's nothing
easy about doing this.

I mean, having
those power tools, yeah,

It's definitely an
advantage over having to file,

But it's still a lot of work
that's got to happen out there.

- As soon as the round starts,

I know that the first thing
I want to get on this knife

Is a handle.

Trying to find
something that I recognize

In this tiny spotlight
is very difficult.

- The first round,
forging in the dark,

You had all these things
that give you light.

- It's even darker
in this round than round one.

- My eyes are immediately
drawn to two blocks of maple

Because it's
a generally reliable hardwood.

But, they are massive.

If this thing doesn't
index in the judges' hands,

Well, they're gonna notice.

So I got to start hogging
away material fast.

Doing this by hand
would be much harder to do.

- Sean's already got
the scales on.

- That is a smart move.

- Praise thor's hairy chest...
I have a grinder.

So immediately,
I started working on

Readdressing my recurve.

If we didn't have power tools,

I would have had
to file by hand.

It is amazing having a grinder.

- What ron's doing right now
that I like

Is he'll do a few passes
with the angle grinder

And then put his hand
on the blade

To see how hot it's getting.

So he's keeping an eye on not
losing his temper... smart move.

- That'll work.

- Thank goodness these
battery powered tools

Are going to allow me to have
a chance of finishing my knife

Within these two hours.

My biggest concern is definitely

The warp in the cutting edge.

So that's the first thing
I'm going to address.

- What are some things
that dan can do

To straighten that tip out?

- Well,
he's got enough material there

That he can
grind a lot of that straight.

- My edge is just about
as straight as I could

Possibly get it,
and I need to move on.

- All right, bladesmiths,
you guys have 90 minutes left

In the second round.

- Once the handle
material is on,

I can start focusing
on my next steps.

Doug told me that he would
like to see that cutting edge

Be brought down
a little bit more.

I have to be
very careful with this process.

If I end up slipping and
taking off too much material

From a place
that can't afford it,

I don't think I can
come back from that.

Hell yeah.

At this point, I'm starting
to feel really good

About how it looks.

I think
I'm about ready to sharpen.

- I've got the pin fitted.

I've got
the scales roughly shaped.

So now I put
an ito wrap on there.

I do a lot of ito wraps
'cause I love how they feel

And I love
the aesthetics of them.

- You don't do
the cord wrap properly,

And the cord wrap starts
to move on that core material,

You've got
a handle that's coming loose.

- 100% of the time I feel
the urge to be creating stuff

Whether it's tattooing myself,
making knives.

I just always have
to have something in my hands

And be creating something.

I finish the ito wrap.

It's not as clean
as I would have liked it,

But it feels
pretty good in the hand.

- For the handle, I wanted
to find a synthetic material

Because I'm used to
using it and I have no idea

What the testing is, so I want
something I'm familiar with.

- That's the wrong tool.

- You got hammers
all over the shop,

Ron's using the c clamp.

- Uh-oh.
- Not good.

- Ron's handle material
just snapped in half.

- At this point, I am terrified.

I don't know how much time
we have left,

And I have to start over.

So I'm frantic.

No!

- Uh-oh.
- Not good.

- Ron's handle material
just snapped in half.

- I have to put scales on this.

So I'm frantic.

I decide
to change the game plan.

I am not going
to use synthetic material.

I'm going to use wood.

- Bladesmiths,
you have 30 minutes left.

Ron is on his
second set of handle scales.

Let's see if this one's a charm.

- I'm starting over.
I am very nervous.

I don't know if I can
complete this in the time left.

- I am in love with
the shape of this knife,

But it has to be sharp enough

For whatever test
they come up with.

- How hard is it, really,
to get that fine edge

With an angle grinder?
- Hard.

One of the things
these smiths ought to do

Is start using the stones.

That way they're gonna
have a nice clean smooth edge

As opposed to
a 36-grit flat wheel edge.

- I use the whetstone
because we still don't have

Power for the grinders,
and I really don't want to

Risk overheating it
with an angle grinder.

She shaves hair.

I am ecstatic.

If a blade is sharp enough
to pull this hair off

Your arm,
you know that it's gonna

Be sharp enough to cut anything.

Okay, we're real close.

- I need to get a sharp blade,

But I'm not super comfortable
with whetstones.

- Dan grabbed belts.

We don't have the belt
grinders going,

But we didn't say
he couldn't use the equipment

That goes on them.
- Shoe shining with those belts

Is a great idea.
- Yep.

- I'm trying to slack grind
as much as possible.

I feel more confident
that that would build up

A micro-cutting edge.

Hopefully it functions well
under testing.

- My new handle goes on faster
than I had thought,

Which makes me happy.

But I still want to put
a good edge on the blade.

I start using
pieces of sandpaper

To start profiling the edge
a little bit.

It's incredibly slow,

But I think it's almost there.

- Would you look at that,
guys, the power's back on.

Just in time too.

Five, four, three, two, one.

Bladesmiths,
put down your tools.

This round is officially over.

Very well done.

- I am elated.
I am excited.

I had to start over,
and I still made it in time.

- All right gentlemen, it's
time for the strength test.

And sticking
with our blackout theme,

The flashlight chop.

Dan, you're up first, you ready?

- Absolutely.
- Okay.

- The moment I see
all the flashlights,

I'm thinking this is gonna be
a little more brutal

Than I was expecting.

I have no idea
what my blade is gonna do

Up against those flashlights.

- Right, so, dan, that's
a really nicely designed blade.

As far as how well
your blade held up,

It's still true,
it's still got an edge.

Might have a little bit
of dulling right here.

But you do have a crack
in the blade.

When I run my finger on this
side of the blade,

I can feel it.

The edge of the blade
has moved just slightly away

From that crack.

Beyond that,
I think you did a great job.

Well done.
- Thank you.

- All right, sean,
your turn, you ready?

- Yes, sir.
- Okay.

- I can't help
but feel anything but anxiety.

If I take any edge rolling,
who knows

How I'm gonna hold up
in the sharpness test?

- All right, sean,
your blade, still straight,

Still in one piece.

And I can feel a lot
of sharp parts on it,

But you've lost some edge.

There's sections of this
where I can rub my finger.

But the blade held together.

Nicely done.
- Thank you, sir.

- Ron. Ready?

Make it go dark.

- I broke my scales
trying to get the scales on.

I'm not confident

That they can even
make it through testing.

I have to survive this.

Survive or go home.

- I broke my scales
trying to get the handle on it

So I hope
that they survive this.

- Ron, I was really worried
about your handle

Going into testing
'cause of the trouble you had

With the broken scales,
but I was wrong.

It's a very comfortable handle.

As far as your edge goes,

I can run my
fingernail down this

And not feel any damage at all.

Really, really good job.
- Thank you.

- All right, bladesmiths,
this is the sharpness test...

The fire blanket slice.

Dan, you're up first.
You ready for this?

- Absolutely.
- Let's do this.

Right, dan, let's talk about
your blade here.

The front section
right here is very sharp,

But that one area where
you have this little crack,

It did give us some
of these jagged edge cuts.

And, of course, this area
right underneath the belly,

On the last cut,
that's the reason

Why it didn't cut all the way
because it's dull in this area.

But overall, your weapon,
it will cut.

All right, sean,
your turn, you ready?

- Yes, sir.
- Let's do this.

All right, sean, your edge...
Some sections of this

Didn't cut
where it meets a dull area,

But where the edges
are sharp... it will cut.

- Thank you, sir.

- Ron, your turn.
You ready?

- Yes, I am.
- Let's do this.

- My wife told me that if
I made it to the second round

Of testing,
and if doug does not say,

"it will cut,"
I am not to come home.

So I hope my blade cuts well.

- All right, ron, your edge,
because it's a tooth grind,

It wasn't a razor cut
on the last slash.

But the rest of the cuts...

It will cut.

- Awesome.

- Bladesmiths,
I gotta say right off the bat,

It's been an absolute pleasure

Watching all three
of you guys work your ways

Through a very unique challenge.

Our judges have
discussed your blades

And they made a final decision.

The bladesmith
leaving the forge is...

Dan, unfortunately,
your blade didn't make the cut,

And dave baker's
gonna tell you why.

- Dan, you designed and built

An absolutely
beautiful blade by hand,

And I'm really impressed
with your work.

But it looks to me
like that heat treat

Was too high on that w1

And that crack formed,
and that's a structural issue

That your competitors
just don't have.

That's why we're letting you go.

- Dan, you're
an unbelievably talented smith.

It's been
a pleasure watching you work,

But unfortunately,
I'm gonna have to ask you

To please step
off the forge floor.

- Thank you.
- Thank you.

- Good job, dan.

- I absolutely agree
with the judges' decision.

But I had a lot of fun
in this competition.

I'm just not a big grinner,

But I'm certainly
having a good time.

- Sean, ron, congratulations.

Your hard work has paid off
and you are both moving forward

In the third and final rounds
of this competition.

Now at this point,
you get to go back

To your home forges
for four days,

Using your tools and your
electricity to build this...

The sword of mercy.

- Whew.

- The sword of mercy,
also known as curtana,

Has been used as a coronation
sword since the middle ages.

The ceremonial blade

Is defined
by its square-blunted tip.

Legend has it,
the sword was broken off

By an angel
to prevent a wrongful killing

And therefore symbolizes
the mercy it's named for.

To this day,
this benevolent blade

Is one of the crown jewels
of the united kingdom

And is still in use
in coronations

With kings and queens today,

Although even commoners
can see it on display

In the jewel house
at the tower of london.

- Your blades measure from tip
to where the cutting edge ends,

And a straight line needs
to be between 29 and 31 inches.

Needs to be double-edged,
have a blunt, flattened tip.

- The most interesting
thing about this sword

Is the blunt tip.

I've never made a sword
with a blunt tip.

So I'm very nervous,
but I'm equally excited.

- One of you guys is gonna
leave here with the title

Of "forged in fire" champion
and a check for $10,000.

So good luck, guys.
We will see you in four days.

- Here I am in castle rock,
colorado,

Back in my half
of my mom's garage.

Today we are making
the sword of mercy.

That's a ton of steel.

Doing damascus was
really important to me,

Because I knew
that at the end of the day

If my blade
and my competitor's blade

Performed the same,

It was gonna come down
to craftsmanship.

I think this is
a solid build of steel.

At the end of the day,
I've been able to forge out

The rough shape of the blade,
but I should be able

To finish
early in the morning tomorrow.

We're getting to a good place.

- Here I am, I'm back
in my hometown eugene, oregon.

I'm getting ready to build
the sword of mercy.

The original sword
is a damascus.

It's a single mono steel.

So since I'm doing
an actual reproduction,

I wanna spend as much time
as I can

To make sure I'm making this

As historically accurate
as I can.

I don't have a power hammer
or a press,

So my biggest challenge
is going to be

Just getting the shape I want.

That's good.

In round one and two,
we had no power,

So similar
to my home build here.

I'm able to move half
of the length of the steel

I'm working with.

So tomorrow, it's gonna
move a lot faster, I think.

- Today is day two.

Today, we're gonna be working on

Getting that blade quenched.

Yeah, I'm exactly
where I want to be.

It is very weird that
the blade does not have a tip.

I've never been great at
grinding double bevel tips.

So, I was actually
kind of happy to see it.

I have this blade
forged out to shape

And ready for quench.

The more normalizing cycles
I have to do

On this blade,
the more I realize

It's gonna be a bitch
to get it all up to temp

And ready for quench.

I've never had to quench
a blade this big.

This quench is worrying me
more and more.

I'm terrified.

There's not much I can do.
I can't start over.

I'm definitely panicking inside.

It's hard.

The blade is great.

This thing hardened as much
as it needed to,

Which I am relieved to hear.

That's a victory in my book.

- Day three, morning.

Yesterday, I got my blade done

And finished the handle
and the pommel.

So I'm really happy.

My main focus is to get
the handguard finished today.

The cruciform guard
has some twisting on that.

That can take some time.

So I want to make sure that
I had as much time as possible.

So as I'm hammering this out,
I'm noticing I'm starting

To get a crack on both sides
of where I'm shaping this.

The biggest issue
it's going to have is

On a strength test...
More chance of it breaking.

If the blade fails...

I'm out.

- As I'm
hammering out my hand guard...

I see some cracks
have started developing.

This is a nightmare.

I decide I'm going to scrap it.

Two hours has been a waste.

I enjoy being able
to hand forge things,

But I need to start
making some progress.

I cut the shape
that I roughly need,

And it's looking pretty good.

On the money.
Okay, good.

End of day three, and I have all

The different
little pieces done.

All in all,
I feel really confident.

- Today is day four.

We are in the final stretch.

The first thing I gotta do
is the wire wrap.

The wire's constantly
gonna want to unravel on me.

So for the time being,
and my plan is to

Just kind of brute force it
until it starts working.

I'd rather spend this time
inventing a time machine

To go kill whoever
decided this was a good idea.

Dave baker is very picky

About the way things
feel in his hands.

So I want to make sure
this thing feels phenomenal.

I want to give him
as little reason

To complain as possible.

Looks kind of cool.

All that's left is getting
everything together.

As long as it holds up,
I should do well.

Hell yeah.

- Day four.

Today, I can just focus on

Finishing up, sharpening up,

And putting everything together
without any hiccups.

So far, so good.

Everything is going
right and tight.

Finally at the finish line,
it's done.

I really like the way it looks,

And I think it'll hold out
in the testing.

- Well, sean, ron, gentlemen,
welcome back to the forge.

We gave you four days
at your home forges

To build your swords of mercy.

Now before we get into testing,
I want to hear about them.

So ron,
tell us about your blade.

- My blade's 5160 steel,

Brass brush mild-steel fittings,

Wire wrap handle
and cruciform guard.

- Awesome.
Sean, how about you?

- I have 26 layers
of 15n20 and 1095.

5160 guard, mild-steel pommel,

And a wire-wrapped maple handle.

- Awesome.

All right, gentlemen, one of you

Is gonna be leaving here
with the title

Of "forged in fire" champion

Carrying a check for $10,000.

The best way we know how
to find out which one of you

Will take home the title today...

By putting them through
a few tests.

But first, it's the keal.
Doug?

- Bladesmiths,
welcome to the keal test.

Ron, you're up first,
you ready for this?

- Make some pork chops.

There's some thick
bones in there

That I can be concerned with.

I'm just doing everything
I can to maintain composure

At this point.

- All right, ron, let's talk
about your sword of mercy here.

These are sharp chops.

Each cut was very deep.

Followed by the nice weight
that's backing up the sword,

It cuts deep
into this big carcass.

And of course as you can see,
it's easy to wield

And follow through
and control your weapon.

Overall, sir, your weapon...

It will keal.

- Yeah!

- All right, sean,
your turn, you ready?

- Yes, sir.
- Let's do this.

- I'm pretty nervous.

I know these pigs can
be pretty gnarly to blades,

So I'm just hoping
the mind goes clean through.

- All right, sean, let's talk
about your sword of mercy here.

I'm able to hold on to it.

I can tell where the edge is.

But your blade, sir,
is not very sharp.

As you can see
the first cuts right there,

It's more from
blunt force trauma.

But as you can see with
the first sections just here,

You have some spots
that are sharp,

And that, sir,
is what made your blade...

Keal.

- Bladesmiths,
welcome to our strength test,

The throne chop.

Ron, you're up first.

You look excited.
- Oh yeah.

Let's overthrow the monarchy.

- Let's do it.

All right, ron, good job.

Edges are still razor sharp.

But that shock wave's
traveling all the way

Down this blade and...

your guard's loose now.

But it was comfortable
in the hand.

Good job.
- Thank you.

- Sean, how you feeling?

- Awful.

- Let's hope you feel
better in a few minutes.

- Let's hope.

I'm feeling very nervous
going into this test.

J. Does not pull any punches

When it comes to
swinging these swords.

I'm just hoping
that everything holds up.

I'm feeling very nervous.

J. Does not pull any punches

When it comes to
swinging these swords.

I'm just hoping
that everything holds up.

- Good job.
- Thank you.

- All right, sean,
it's all in one piece.

Gotta be proud of that.

Your blade is still straight
this way.

Not this way.

Your handle, it's not loose,

But it's definitely separated

From the base of the handle now.

But, like I said,
it's still in one piece.

Good job.
- Thank you, sir.

- All right, bladesmiths,
now it's time

To find out just how
sharp your weapons are.

This is the sharpness test...

The tapestry slice.

Ron, you're up first, you ready?

- Oh yeah, let's make it pretty.

- All right, let's do it.

- Well done.
- Thank you.

- All right, ron, first up,

It is loose,

But it did not affect my test.

Overall, sir, your edge...

It will cut.

- Awesome.

- All right, sean,
your turn, you ready?

- Yes, sir.
- Let's do this.

All right, sean,
around this area right here

You have some sharp edges.

So you can see in the first
cut here in this tapestry,

It cut in, but when
I'm dragging it through,

It just stops its cut.

But, it still did cut so...

It will cut.

- Thank you, sir.

- Well, bladesmiths, this has
been a good competition

Right from the very beginning.

But as you know,
only one of you guys

Can leave here with the title
of "forged in fire" champion

Carrying a check for $10,000.

Now our judges
discussed your blades,

And I'm not going to leave you
in the dark any longer.

Today's "forged in fire"
champion is...

Ron, congratulations.

Now, sean, you fought hard,
you're a talented smith,

But unfortunately your blade
did not make the cut,

And doug's gonna tell you why.

- Sean, first off,
I have to commend you.

That's a nice damascus baton
you have there.

But during our test,
your blade took some bends.

It also underperformed
in the keal and sharpness test,

And for those reasons,
we're letting you go.

- I understand completely.

- But sean,
we hope you had as much fun

In this forge
as we had watching you.

But unfortunately this time,
I'm going to have to ask you

To please step
off the forge floor.

- Thank you all for having me.

- Thank you.
- Good job.

- I thought that
the whole thing was sharp,

And guess I was wrong.

I'm definitely gonna go home,
bust out a bunch of knives

And make sure all those
suckers are sharp as hell.

- Ron, congratulations.

That makes you the
"forged in fire" champion, man,

And you got a check for $10,000.

Congratulations.

- I'm... I'm so proud.

I would encourage anyone to
come and try this experience.

It doesn't matter whether
you're new to bladesmithing

Or you're a seasoned veteran.

If I can do it at 50,
you can do it at 25.

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