All language subtitles for Forged.in.Fire.S09E09.720p.WEB.h264-BAE

- My name is stephanie aiuto.
I'm 31 years old.

I live in new york city,
and I'm a part-time bladesmith.

I've always had an appreciation
for knives and armor.

So I googled, you know,
"new york city bladesmith"

And I found theo nazz,

Who's a former contestant
on "forged in fire."

He won his round back
in season three

And then his champion's round.

And yeah, now we're
just forging buddies,

And I'm happy to keep
making new knives.

- My name's nathan butcher.
I'm 47 years old.

I'm a locksmith
from bartlesville, oklahoma.

Bladesmithing is a hobby that
I've been doing for 33 years.

But it's kind of dangerous,

So I have plastic lenses
in my eyes

From looking into a forge
for years and years.

I've had a heatstroke, and...

I can only count to nine.

- My name is jason lyle.
I'm 41 years old.

I live in
jonesborough, tennessee.

I'm a part-time bladesmith,

A full-time first responder.

My job helps me cope
with things different

Than other people,
as far as stress,

So I think it could play a
helping role in my challenge.

- My name is adam till.
I'm 39 years old.

I'm from gadsden, alabama.

I got into bladesmithing because

I got tired of paying
a lot of money for knives

That would not hold up
to the use

That I was putting on them,
and I've always been told,

"if you could do it better,
do it yourself."

- Bladesmiths,
welcome to the forge.

You came here to compete
against each other

And against our clock
in three intense rounds

Of forging competition.
After each of the three rounds,

I'm gonna ask you
to present your work

To our panel of expert judges,

Who will then critique your
work and make an elimination.

Now, the judges today are

Expert blacksmith and
bladesmith ben abbott,

Historic weapons re-creation
specialist dave baker,

And edged weapons specialist
doug marcaida.

These are the men
who will be deciding

Who's gonna be going home
with the title

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

So let's cut to the chase.
In this competition,

We want you guys to put
together a signature choppe.

But when you're building
your choppers,

We want them to fall within
the following parameters:

Your blades need to measure
between 13 and 15 inches.

But we got a bit of a problem.

You see, the only
high-carbon steel

We have available is this.

Just a sliver of 1095.

But we totally understand
it is impossible for you

To put together a chopper of
the dimensions we're asking for

Using only this high-carbon.

We want you guys to source

The rest of your materials
from this.

Bladesmiths, what we have here
is a pile of scrap steel.

Some of it's usable mild
and some of it

Is unusable cast iron.
What we want you to do

Is source the bulk of your
materials from this pile here,

Turn it into a billet,

Forge weld your high-carbon
on there as an edge,

And turn it into a blade.

- Wow. This is definitely
gonna be a challenge.

The big challenge is setting
a weld that long.

It's definitely a hard task
for anybody.

- In the second round
of the competition,

You're gonna add handles
to your choppers,

Turning them
into fully-functioning blades,

At which point the judges
are gonna check for strength

And durability
in a steel rebar chop,

And they're gonna check
your edge retention

In a ballistics tube slice.

We've got three hours
on the clock

For this first round
of competition.

So good luck. Work hard.
Your time starts now.

So it all looks like
junk metal to me.

What should they be looking for?

- If it looks structural...
Like, angle iron, tube,

Stuff like that,
it's generally mild steel.

- First thing comes in my head
is find the biggest piece

Of mild steel
laying on that table.

I'm looking for something
that's gonna be flat

And thick enough
that I could insert

A bit of
the high-carbon steel into.

I just know the angle iron
was made from mild steel,

And the plan
is to edge weld to it

And draw out a knife
from that piece of steel.

- Well, nathan and adam
both have that angle iron.

But that stuff's super thick.

- Yeah. It's a fat 1/4 inch.

- I'ma go with this piece
right here.

I find a basic round stock
that I knew was mild steel

As soon as I looked at it.
I know I need to figure out

How much I need
to make that parameter.

My plan with this mild steel
and high-carbon...

Go ahead and forge out
somewhat of a shape

With the mild steel,

Cut a groove down it,
insert my high-carbon bit,

Forge weld together.

- The smiths more than likely
didn't practice this

Before they came here.

- I do this all the time.

I love this method
of construction.

- I need to figure out a way
to stick the tiny little piece

Of high-carbon
onto a big piece of angle iron.

This will do.

I'm gonna cut it in half,
and I'm gonna put it together

So it will be roughly the sae
thickness as my mild steel.

- Nathan just cut his
high-carbon sliver in half.

Feels silly.
Why would he do that?

- He's probably look at it
as too long a weld.

The length of the weld
is what's making him nervous,

I would assume.

- I've got my three pieces
all tack welded together.

Now I'm gonna put it in the
forge and set my forge welds.

- I need to find something
wide enough

So I can set
that carbon bit in it.

I see this square tube.

If I can use an angle grinder
and cut off one section,

That'll be enough that I can
draw out a blade to parameters.

- Stephanie's got tube stock,

Kind of like what we use
for the canisters.

- I worry about that tube stock

Being a little on the thin side.

'cause remember,
wherever you have that weld,

When you start
to hammer that down,

Everything gets thinner
and thinner and thinner.

So having some meat
where that weld's gonna start

Is a good idea.

- All right.

- Jason's over on the vise
with a chisel.

Making a space to fit
that high-carbon into?

- Yeah. That's right.

- Once I open it, I'ma try
to insert the high-carbon bi,

Put it back together,
do a couple of tack welds,

Then try to forge weld it
into one blade.

- No problems with
potential cold shuts in there?

- No cold shut problems,

But there could be
an issue with cleanliness

If he doesn't clean
that v out completely.

- My biggest concern is not
getting the forge weld

All the way down
the high-carbon bit,

And a lot can go wrong
with splitting apart.

- That's a nice forge weld
temperature.

That's looking good.

- I look, the knife
is coming up to temperature,

So I bring it out,
set the first weld by hand.

I like it.
I've got my weld set.

Now, I've got this huge
rectangular piece of steel.

I'm gonna have to try to
draw it out to meet parameters.

- All right, bladesmiths,
you have two hours left!

- My design's gonna be
just a basic chopper.

No point on it,

Because we're not gonna be
doing any stabbing.

My biggest concern
in the competition

Is am I gonna be able to weld
this high-carbon bit

To this knife shape?

Oh, man, I screwed up.

- Adam's back in the welder,
and his high-carbon steel

Isn't matching
the curve of his blade.

Do you think there's gonna be
cold shuts or unweldable spots?

- Yeah, if it's not clean,
it just might not weld at all.

- I know I gotta close the gaps.

Can't have any gaps.

So I got two choices...
Either to continue working

With what I have
or scrap it and start over.

I know what I can do.

I gotta keep moving forward,

'cause I'm losing too much time
at this point.

So I go ahead and throw
a little extra flux on there

And try to set the welds
by hand.

Oh, yeah.

I'm extremely relieved and
excited all at the same time.

And now I can move on.

- All right, stephanie's going
in the press for that weld set.

- Man, I would set that by hand.

It's a tall weld.
She's setting it on the press,

And it can...
It can buckle it over.

- I'm trying to tap it in
as gently as I can.

I see it is just shearing off
to the sides.

- Stephane's billet
just opened up.

It's not taking.

- Aww, stephanie's having
a rough time over there.

- I've messed up my carbon bit.

Oh.

- There's no chasing it.

The biggest bit of wisdom

That theo gave me
before I came here was,

"you see a problem
that you know you can't fix,

Abandon it while there's
still time on the clock."

So I need to just abandon
this right now

And try something new.

My new plan is to do
something very similar

To how one would put a
high-carbon bit in a hatchet:

Carving in that channel,
and placing it in.

- I've got my welds set,

So I'm gonna basically
draw it out into a bar

Until I'm ready
to forge the point.

It's gonna be heavy,
so I'm gonna forge it heavy,

Because it's easier
to remove the material

Than it is to put it back.

I have to make a chopper,
but I want it to have a point.

I was told to make it
in my style.

My style has a point.

This is starting to look
exactly the way I want it.

- I'm not real happy
with the shape of my blade.

But if I can get this thing
quenched and hardened,

I can work on the shape.

- Adam just quenched.

- Come straight out of the oil,

And I head straight
to the grinder,

Because I wanted to see
how much high-carbon steel

I had down toward the edge.

I have a little sliver
of high-carbon there,

So I'm trying to be
extremely cautious.

I seen too many smiths
in the past get sent home

For having mild steel
that's on the edge.

- The shape I'm doing is just
a standard competition chopper.

It's nothing fancy.
It's not hard to do.

I got my width.
The forge welds look nice.

I'm getting ready to quench.

- All right, jason quenched.

- Soon as I pull it out, I see
it's already starting to warp.

I've got to do something
about that.

So I went straight over
to the grinder

To try to take
some of the warp out.

- All right, stephanie's going
in the press for that weld set.

- Not the press.
Oh, not the press.

I'm having a bit of trouble
getting this forge weld to set.

Okay.

- She looks like she's getting
pretty frustrated.

- So I'm going to have
to beat it into submission

Until I've mushed
those two pieces together.

- Stephanie's got on
a good finessing touch.

- Wish she would have found
this two hours ago,

When she started
working on the press.

- I finally get this forge
weld to set.

Okay.

There's a little bit
of a weld issue at the ends,

But I can always
grind those off.

The heart of this blade
is one piece.

I'm feeling good right now.

- All right, bladesmiths,
coming down to the wire!

You have 30 minutes left!
Three zero!

- It's time to get
ready and quench.

I don't know what
the stresses will do

With the two different kinds
of metal.

It could pop my edge right off.

- Here we go.
All right, nathan quenched.

- I take it out, and once
I get through the smoke,

It looks pretty straight.

With the time I have,
I'm gonna grind on my blade.

It's heavy.
It needs to be lightened a lot.

But I'm happy with the shape.
I'm happy with the point.

I'm happy with everything.

- I'm not real super happy
about the shape.

Wish I had a little bit more
time to make it prettier.

But it's time to acid etch.

I'm wanting to look for
the little brown circles.

That definitely indicates that
you had a failed forge weld.

I'm not seeing any red spots
coming out from the forge weld,

So I'm really happy
at this time.

- Now we have a knife.
It weighs a ton,

Because I haven't removed
enough material,

But the knife looks right now.

- Stephanie just quenched.

- It's mostly straight,
but I'm just gonna bring it

Straight to the grinder
and profile my blade.

There's not a whole lot of time
left on the clock,

But I'm hopeful and I'm happy.

- Bladesmiths,
you have five minutes

Before turn in and critique!

- As I'm working on the grinder,

I seen the seam
where the mild steel

Was pulled back a little bit
from the high-carbon.

See the high-carbon?

I'm thinking I should
go over there

And mig weld it
to make sure there's no delams.

I look up at the clock.

I don't have enough time
to address it.

But that could cost me.

- Five. Four.

Three. Two. One.

Bladesmiths,
turn off your tools.

Put down your blades.
This round is over.

- Ugh.

Going into judging, I know
the seam don't look good.

But now it's all up
in their hands.

- All right, bladesmiths,

In the first three hours
of this competition,

All four of you
were successfully able to take

That high-carbon steel

And forge weld it
onto your mild steel blades.

You all have blades
that meet our parameters,

But the time has come
for the judges

To decide which three of you
will be joining us

In the second round
of this competition.

Stephanie, you're up first.
You ready?

- Yes, sir.
- Please present your work.

- All right, stephanie,
you had a problem

Trying to put your
hardenable steel on the edge,

But you found a solution.
Good on you.

But you still have
a delamination.

If you move forward,
you should address that

So that in our test,
it doesn't open up anymor.

Good job.

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

- Yes, sir.
- Please present your work.

- All right, nathan, the shape
of your blade is really good.

Just a very classic
chopping camp knife.

The big issue I have
with this knife is the weight.

This is a very
heavy blade still.

A lot of this weight
needs to come off of here.

And combined with
a big, heavy knife like this,

This handle is on
the smaller side.

In general, it's a good-looking
piece of steel.

The welds are solid.
Nice job.

- Thank you.

- All right, jason,
you're up next.

Please present your work.

- Right off the bat,
great shape.

Like a big hog splitter knife.

The biggest thing
I take issue with

Is there are a couple places

Where you've got sort of
that delam ridge line.

I mean, down here, I can get
a fingernail in there.

But as a chopper,
it's a great shape.

Good job.
- Thank you.

- All right, adam,
you're up next.

Please present your work.

- All right, adam.

You've got an interesting
shape going on here.

This is another blade
where the steel was welded

Directly down
onto the mild steel.

So you really can't do
all that much profiling

With this edge without,
you know,

Kind of grinding into the mild,
but in general,

I think you're set up for

An interesting-looking chopper.

Nice job.

- Well, bladesmiths,
first off, I want to say

You guys all have a lot
to be proud of.

We gave you a very difficult
and unique challenge,

Asking you to take a tiny bit
of high-carbon steel

And somehow turning it into
a functional chopper.

But in this competition,
only three of you

Can join us in the next round.

The bladesmith who's gonna
be leaving the forge is...

Jason.
Unfortunately, your blade

Didn't make the cut today,
and doug's gonna tell you why.

- Jason, first off, I want to
thank you for battling through

And turning in
a pretty good design

For a competition chopper.

But your blade has the most
visible delaminations

Along the weld line.

For that reason,
we're sending you home.

- Totally agree. Thank you.

- Well, jason, you had
the process all down,

But unfortunately, man,
you're not gonna be joining us

In the next round
of this competition.

I'm gonna have to ask you
to please surrender your work

And step off the forge floor.

- I practiced for weeks
on all my canister,

Regular damascus, san mai,
and then they threw a curveball

Of putting a small piece
of high-carbon

Down a full-length blade
into mild steel.

But I have no regrets.

I had a blast,
and I'll keep on bladesmithing.

- All right, bladesmiths,
congratulations.

The three of you are joining us

In the second round
of this competition.

Now, in this round we want you
to fix any issues

That you have with your blades
as well as add handles to the,

Turning them into
fully-functioning chopper.

When this round is complete,

You're gonna turn your blades
over to our judges,

Who are gonna check
for strength and durability

In a steel rebar chop.

Then they're gonna check
your edge retention

In a ballistics tube slice.

All right, bladesmiths,
you have two hours on the clock

For the second round.
Good luck.

Your time starts now.

All right.

So they're all... seem
to be fairly well set up.

We got a couple minor issues
that need to be attended to.

- Yeah. Stephanie is
really nicely set up.

She could fill that one gap
with some weld, clean that up,

And put a handle on it,
and be ready to go.

- Stephanie's taking care
of that gap

She's got in her blade between
the mild and high-carbon steel.

- Great. That's great.
- That's a really smart move.

- Put a few drops of beads in,
build up a base,

That way I can bring it
to the grinder,

And then grind it flat
and be fine.

- Nathan has maybe a pound
to take off of that blade.

- First thing I'm gonna do,
I need to lighten the blade.

It's heavy. It's thick.
I need to thin it down.

And then I'll start the handle.

- Look at that mound of sparks

That nathan's got
by the grinder.

- I've been grinding
on the blade

For about 30 minutes.

It feels good. I'm happy.

- First thing I want
to address right off the bat

Is the shape of the knife.

I'm gonna mark
where I want to cut at,

And then I'm gonna wrap it
in a paper towel

To try to keep the tip
from overheating.

I can make this thing
look pretty decent

For the kind of work I do.

- Well, look at that. Look at
the difference in that knif.

That's really impressive.

- I'm pretty happy
with the shape,

And now I can move on
to putting the handle on.

- Going over to the pantry,
the first thing

I want to make sure
is that my block of wood

Is going to withstand the
football spike test that I do.

- That's one way to find out
how hard it is.

- I'm at the bandsaw,
and it's taking time.

I know it's going to take time.

- You see how long it's taking
stephanie to cut that wood.

- I would really be using
the portaband

Instead of that bandsaw.

The portabands have
a more aggressive teeth,

And they've got
a long enough throat

That you can make this cut.

- It's just so slow,
and I'm looking at the clock,

And 30 minutes are already gone.

- You got time.

Slow and steady.

- I finally get two pieces
that are usable.

I can keep moving forward.
Let's do this.

- Bladesmiths, you are halfway
through this handle round.

You have one hour remaining
before testing.

- I need to make
my handle bigger

To make the judges happy.

So my plan is to take a piece
off of a mild steel angle iron

And weld that onto the bottom
side of the handle.

That is never gonna cut.

The portaband is not cutting.

Hell, no.

- Looks like nate is really
struggling

To cut a piece of mild steel
at his portaband.

- Well, nathan's using
the right tool,

But he's just not moving
fast enough.

He's gotta get this done now.

- It's pissing me off.
That is awful.

The clock is ticking,

So I've gotta figure out
something else right now.

Uh...

So I abandon that
and go to the welder.

- Nathan is taking mig wire
and building up,

Slowly, in layers,
to make his handle wider.

- That'll have to do.

- I got about a half hour left,

And I still got to shape
my handles, sharpen my blade,

And then I have to get it ready
to present to the judges.

The handle, to me,
is really important.

It's just as important
as the edge on the blade.

So I don't want it to feel
like a broomstick.

I want it to feel comfortable

And like it's not gonna slip
out of their hand.

- Adam's taking
a ton of material

Off his handle scales.

- Yeah, adam's handle seems
a little bit narrow.

- My handle's looking good
at this time,

And now I can move on.

- All right, bladesmiths,

You are down to 30 minutes left.

Keep on working.

- I've got my handle on.
I've got my pins set.

Now I've gotta shape the handle,

Try to get rid of any hotspots,

Round it up, smooth it up,
try to make it fit the hand,

Because if I was to give them
the handle that was just round

There's a chance that it will
roll in their hand

And it could cause a bad test
or somebody to get hurt.

And the last thing I'd want
to do is to hurt a judge.

I've got my handle done.
It feels good in my hand.

It's time to move on.

I need to put an edge
on this thing.

Okay.

- I look up at the clock,
and I'm like,

"oh, my god,
I gotta sharpen this blade."

I still have a little sliver
of high-carbon there,

So it should retain its edge.

But I kind of wish we had
a little bit more high-carbon.

I don't want to take away
any high-carbon steel.

Then we got a mild steel knife,
which isn't quite a knife.

- Five. Four.

Three. Two. One.

Bladesmiths,
put down your tools.

This round is over.

- I feel pretty proud
with the work

That I was able to accomplis.

Given what I had,

I'm pretty happy
with the work I've done.

- All right, bladesmiths,
welcome to the strength test:

The rebar chop.

To test the strength
and durability of your edge

As well as the overall
construction of your blades,

I'll be chopping
into these rebar.

Adam, you're up first.
You ready?

- Might as well be.

- All right.

- Last time I checked,
I really didn't have

That much high-carbon left
out the edge of my blade.

I'm just really hoping to make
it through the strength test.

- All right, adam.

First off, this is a tough test.

I think we all know that.

And you brought your edge
down to a really fine edge,

And the test won
a whole bunch of times.

Everywhere I hit on this blade
left a piece in that reba.

The handle,
it's on the small side,

And a couple of times,

That blade twisted in my hand
as I was hitting.

But blade's all in one piece,

And it's got a good
overall shape to it.

Nice job.

All right, nathan,
you ready for this?

- You bet.

- Cool.

- Rebar sucks.

There is no reason
to be chopping on rebar.

My blade could break.
The edge could fall off.

It could just...
It could... it could be over.

- Well, nathan, first off,
you did a really good job

Of taking most of that
weight off

And bulking up your handle
to make it comfortable.

Moving on to your blade,
three hits did minimal damage.

But in all, I think you made
a good knife for this test.

Nice job.

- Thank you.

- All right, stephanie.
You ready for this?

I don't have a choice.

That's true. That's true.

- I had a big struggle
getting those

Two pieces welded together,
so there's a big possibility

That I could end up
with two blades after this...

A little carbon bit
and a chunk of mild steel.

- All right, stephanie.

Well, your edge
took some damage.

Right at the very edge,

There is some chipping
from the test.

There's a couple of spots
that I see

Some of the unwelded steel
right here,

That's just moved
a little bit in this test.

But in all, it held up well.

All in one piece.
Nice job.

- Thank you, sir.

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

The ballistic tube slice.

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

- Yes, sir.
- All right, let's do this.

All right, adam, let's talk
about your weapon here.

Right here on the edges,
where you took some damage,

It's actually still sharp.

And during the cut,
it cut cleanly.

Overall, sir, it'll cut.

- Thank you.

- All right, nathan,
your turn, sir. You ready?

- You bet.
- All right, let's do thi.

All right, nathan, let's talk
about your weapon here.

Despite having those rolls,
it actually was not an issue

In cutting on
these ballistics tubes.

Overall, sir, your weapon,
it will cut.

- Thank you.

- All right, stephanie,
your turn. You ready?

- Yes, sir.
- All right, let's do this.

All right, stephanie, let's
talk about your chopper her.

Despite taking some damage
on the strength test,

It was not a factor
in cutting these tubes.

Overall, ma'am,
your weapon will cut.

- Thank you, sir.

- All right, bladesmiths,
the time has come

For the judges to decide which
two of you are gonna join us

In the third and final round
of this competition.

So while they discuss,

I'm gonna ask you to please
step off the forge floor.

All right, guys,
we got three blades

That took damage
in the strength test,

But only two of them
are going in the final round.

Dave, what do you think?

- Adam took a fair amount
of damage on that edge.

And then we've got
stephanie's blade.

She's taken damage,

And it looks like those welds
are cutting loose.

- Ben, what are your thoughts?

- Adam's blade, his handle
was a little small up

Around the first two fingers,

And I lost control a little bit
a couple of times

While I was swinging it.

And it really got eaten up.

Every time it hit the rebar,

It took a big ol' chunk
out of the blade.

- Doug, what do you think?

- It's really between
stephanie and adam,

And adam's seemed to be
bigger damage than the other.

- Well, a decision
has to be made.

Dave, you made yours?
- Yep.

- And ben?
- Yeah.

- How about you, doug?
- Yes, I have.

- All right, guys,
we'll call them back in.

All right, bladesmiths,
the judges have deliberated,

And they made a decision.

The bladesmith who's gonna
be leaving the forge is...

Adam.

Unfortunately, your blade
didn't make the cut,

And ben's gonna tell you why.

- Adam, you ground
a really acute edge on there,

And every time I hit that rebar,

It left pieces of your knife
in there.

That, coupled with
the smaller handle,

Which was more difficult
for me to control,

Really just added up to the
reason we're sending you home.

- Thank you.

- Well, adam,
we want to say thank you

For letting us watch your work,
but unfortunately,

You're not gonna be moving
forward in the competition.

And at this point,
I'm gonna have to ask you

To please step off
the forge floor.

- I agree, for the most part.

A little disappointed, myself.

But at least doug said
"it will cut."

- Well, stephanie, nathan,
congratulations.

It is now down to
the two of you moving forward

Into the third and final round
of this competition.

Now, in this final round,
we're sending you back

To your home forges to build
an iconic weapon from history.

We want you to build this.

Sergeant hayden's sword.

- Sergeant william hayden,
one of the first

English colonists
in 17th century connecticut,

Is best known
for his heroic actions

During the pequot war of 1637.

After rising tensions
between the colonists

And the pequot tribe erupted,

Hayden and a group
of english settlers

Were sent to capture territory

In modern-day
mystic, connecticut.

During the battle,

With a sharp swipe
of his single-edged,

Slightly-curved blade,

Hayden famously cut the string
of a pequot warrior's bow

That was taking direct aim
at the english captain,

John mason, saving his life.

The original historic sword
is still on display today

In connecticut's
historical society museum

In hartford, connecticut.

- It is a very intricate blade,

And the ones you return
should also be intricate,

But make sure they fall
within these parameters.

You need to have
a slightly-curved blade

That measures between
23 and 25 inches.

You need to have fullers
on both sides of your blade.

You need to have a symmetrical
guard that has piercings in I.

- I've never made a blade
like that before,

But it's something that I'm so
looking forward to attempting.

- All right, bladesmiths,

When you come back
to this forge,

We want to see two blades
that are worth at least

$10,000 each,
'cause that's what one of you

Is gonna be walking
out of here with.

So good luck.
We will see you in four day.

- Good luck.
- Good luck.

- I'm back in my home forge.

I'm gonna make
sergeant hayden's sword.

I've got a big day ahead of me.

All right,
we're gonna get started.

Plan is, first day,

We're gonna try to get
the blade forged out,

Try to get it to shape.

Heat, beat, repeat.

I like it so far.

I think we're gonna harden it.

If I don't get
this heat treat right,

I'm gonna have to start over.
I need it to stay straigh.

The edge sounds good,
feels good.

I like it.

I feel like today has gone

Absolutely
as good as it could've.

- Back at my home forge
in industry city,

And I'm super excited
to get started

On sergeant hayden's sword.

Let's do this.
By the end of day one,

I want to have a quenched blade,

So I know the rest of my time
is focused on

Making sure that
that is a perfect blade.

My blade's the right length.
Curve is the right depth.

I'm feeling good,
and I'm ready to quench.

This is the moment of truth.

Just like glass.
Successful quench.

I am feeling good.
I am feeling tired.

But good.

- Day two.
I like my blade,

But I just feel like
it's a little narrow.

I feel like I need
a little bit more mass,

Which unfortunately means

I'll have to forge
another blade.

All right, this is the
beginnings of blade number two.

Hopefully,
I can make it through.

Nothing like having
to do it twice.

I'm getting ready to go
for the quench

And hopefully get it straight.

Well, I'm nervous.

Whew, watch out now.
Watch it.

And it's straight.

I'm happy.

I have successfully made
two sword blades in two days.

- It's day two.
I'm feeling great.

I'm gonna be working on

Getting my guard shaped out
and drilled in.

I've got my mild steel bar
in the forge,

Bringing it up to temp.

Once it's at
the right temperature,

I'm gonna be pressing it down,

Trying to turn a long tube
into a short pancake.

I'm a little behind
where I'd like to be.

Barely made a dent.

I spent a couple of hours
working on my guard,

But it isn't doing
what I want it to do.

I've gotta scrap this
and start fresh.

Time is running out.

I gotta change now or the whole
day's gonna be sunk.

That might work.

Okay.

It's the end of the day.
I'm looking at my guard.

It's a little fugly
at the moment,

But there's nothing
tlc can't fix,

And that's all gonna
happen tomorrow.

- Day four. The last day.

I gotta put it together.

I hope it goes good.
I'm about where I want to be.

I think I've made
a decent replica

Of sergeant hayden's sword.

I've got my sergeant hayden
sword completed.

I feel like I've done
the best that I can.

I hope they like it.

- Day four. Let's get it done.

Today, I want to focus
on fit and finish.

Let's do it.
Slow and steady.

Don't want to break anything.

- All right.
- Hello, boys.

I am ready to show my friends,
theo and justin,

Two former
"forged in fire" contestants.

- Well, that's looking deadly.

Very proud of you.
That looks great.

- Thank you, thank you.

I'm just excited
to see the judges use it.

- Well, stephanie, nathan,
welcome back to the forge.

So you just had four days
to both work

On your sergeant hayden swords,
and they look fantastic.

Before we get into
testing, though,

I want to hear
about these blades.

So, stephanie,
how'd the build go for you?

- The sword went smoothly.

Built with 80crv2 for the blade,

Mild steel for the guard
and the butt cap.

- Good choice.
Nathan, how about you?

How'd the build go?
- It went pretty good.

Blade's 5160.

The butt cap and the guard
are made out

Of etched wrought iron
and with a cocobolo handle.

- Well, smiths,
it is coming down to this:

We've got a strength test,
we've got a sharpness test,

And up first, the keal.

Doug?

- Bladesmiths,
welcome to the keal test.

To find out how lethal
your weapons are,

I'm gonna take your weapons
and deliver some lethal blos

On this ballistics dummy.

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

- Go have your fun.

- You bet I will.

- I'm super excited
to see it get tested.

Making chef's knives,
they don't really

Get the same test
that you do here at the forg.

I can't wait to see
what doug does with it.

Cool.

- All right, stephanie, let's
talk about your sword her.

Your edge is sharp.

I mean, that's one
of the cleanest decapitations

I've done with a sword.

Overall, your weapon,
it will keal.

- Thank you.

- All right, nathan,
are you ready?

It's your turn, sir.
- You bet.

When doug takes
the head off of the dummy

With stephanie's sword,

My sword is gonna have
to keep up with this.

Everything can go wrong
hitting the ballistics dummy.

The blade could shatter.

It could break off at the guard.

It could just cause
a catastrophic failure

In every way.

- All right, nathan, let's talk
about your sword here.

Those are very deep cuts.
Every swing penetrated deep.

Every thrust went
all the way through.

Your weapon, sir, it will keal.

- Thank you.

- All right, bladesmiths,
you know what time it is.

It's time for the strength test.

To test the strength
and durability of your blades,

I'll be attacking
our wooden palisades here.

Stephanie, you're up first.
You ready?

- Oh, yeah.
- Yeah? All right.

All right, so, stephanie,
in the test,

Your blade held up really well.
There's one small chip it took,

And then maybe a little bit
of a glinting spot here,

But it's still sharp.

We get back to here, your tang
kind of kicks this way

And then sort of curves
back this way,

And what that does
is every time I hit,

It kind of rides forward
into that guard.

Didn't really hurt my knuckle,

But over time,
it's gonna be an issue.

But everything's tight.

It held up really well
in this test. Good job.

- Thank you.

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

- You bet.

- So, nathan,
really nicely done.

I ran my fingernail
down that blade,

And I cannot feel
any deformation,

Any knicks, nothing,
so it's pristine.

Your handle shape... comfortable.
It's got that nice flair to it.

The guard's out of my way,
so I'm not hitting it.

Nicely done.
Good sword.

- Thank you.

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

The fish slice.

Now, a sharp edge
should be able to cut

All the way through this fish,

And that's what I'd like to see.

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

- Go do your thing.

- All right, stephanie, let's
talk about your weapon here.

When cutting through
the salmon, no issues at al.

It cut all the way through.

Now, when we got to the grouper,

Which is a scalier
and thicker fish,

You went more than half.

Overall, it will cut.

- Thank you.

- All right, nathan,
your turn, sir. You ready?

- You bet.

- All right, nathan, let's talk
about your weapon here.

Your edge, when cutting through
the salmon, no resistance.

Easy cuts.

On the grouper,
you cut in more than half.

Overall, your weapon,
it will cut.

- Thank you.

- Well, bladesmiths, in this
third round, we asked you

To go back to your home forges
for four days

And come back with strong,
sharp, sergeant hayden swords,

And you both did it.
Now, in this competition,

Only one of you
can go home the champion,

And our judges
have talked it through,

And they've made a decision.

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

Nathan.
Congratulations, man.

Now, stephanie, unfortunately,

Your blade did not make the cut,

And dave baker's
gonna tell you why.

- Stephanie, you made a blade
you can be proud of.

It tested fantastically.

But in the end, this came down

To a matter of fit
and finish and feel,

And basically, your opponent
just beat you by that much.

But you did a great job.

- Thank you.

- Well, stephanie,
we want to say thank you

For your energy in the forge

And fighting through
to the very end.

You gave us a beautiful blade.

But it did not come out
on top today.

Unfortunately
I'm gonna have to ask you

To please step off
the forge floor.

- This has been a crazy journey.

I'm very proud of my work,

But coming so close
that you can almost taste it,

I definitely want to come back
and give it one more go

To see if I can be
the "forged in fire" champion.

- Well, nathan,
you know what that means, man.

You are
the "forged in fire" champion,

And you just got yourself
a check for $10,000.

Congratulations.

- I cannot believe I won.

I know it happened.
It doesn't quite seem rea.

- How do you feel?

- I have no idea.

Making this weapon,
I put everything I had into it,

Trying to make something nice,
and I'm overwhelmed.

I cannot believe I own.

I'm nathan butcher.

I'm the "forged in fire"
champion.

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