All language subtitles for Forged.in.Fire.S09E19.1080p.WEB.h264-KOGi

- My name is Gregory McClure.

I am 50 years old.

I'm from Dacoma, Oklahoma.

Knife making has always been
a deep-seated passion.

My grandfather pulled me in
when I was 10 years old.

We found a piece of metal
alongside the road,

and ever since then,
I started making custom knives.

- My name's Eric Finch.
I'm 20 years old.

I'm from Harmony, Pennsylvania,
and I've been bladesmithing

for almost three years.

When I first got into
bladesmithing,

I didn't have a lot of money,

and my uncle Chuck,

he was super supportive.

He got me my first anvil.

He really had a lot of faith
in me getting into this,

and so being here, it feels
like its finally rewarding him

for what he's done for me.

- How are we doing today?

- Doin' good.
Ready to do this.

All right.

- My name is LJ Jarrett,
49 years old,

from the little town of
Campbell, Missouri.

I was always a bigger guy.

Buddies call me
"Knuckle-Dragger,"

"Mongo," "Kong."

It's kind of where the
Silverback Blades came from,

my little business...

'cause I've always heard
the gorilla jokes.

- My name is Nathan Payne.

I've been bladesmithing
for about four years now,

and I'm from Sparta, Tennessee.

So I'm a full-time employee
with the Department

of Mental Health
and Substance Abuse.

Well, I'm in recovery, myself,

from active substance use

for a little
over nine years now,

and when I found bladesmithing,

it just did something for me.

It was unlike any other
coping mechanism that I found.

- Bladesmiths,
welcome to The Forge.

Now, gentlemen, the four of you
are here to test your resolve

and your skills in a
bladesmithing competition

that consists of three rounds,

each of which will end in
a critique and an elimination

by the judges sitting behind me.

They'll be making the critical
decisions here today

as to who's leaving The Forge
carrying a check for $10,000

and earning the title of
"Forged in Fire Champion."

Now, gentlemen, as you can see,

we got a bit of a Western theme
here in the competition today.

It's all about
speed and accuracy.

This is a competition we are
calling "The Fastest Blade

in the West."

Now, in order
to complete this challenge,

you're gonna need this.

You might be
wondering to yourselves,

"Well, what in tarnations

could I be needing
an empty sheath for?"

Hold your horses.
We're gonna get there.

First,
I want to show you the blade

that fits inside of that sheath.

The Mexican Bowie Knife.

- The Mexican Bowie Knife
was the staple sidearm

of the vaqueros... the original
cowboys of the Wild West.

Getting its shape
from the Spanish navaja,

it traces its origins
back to the 19th century.

This uniquely coated
blade with a clip point

that is small enough
to carry on the belt,

but also sharp enough to cut

through anything
on the frontier,

from ropes to baling twine
to the head of a rattlesnake.

Almost everything, from
the clothes they made

that the cowboys wore
and the knives they carried,

were influenced by the vaqueros.

- Now your test today
is to recreate this blade

as closely as possible,
but as quickly as possible.

Now, as far as steel goes,
the saloon's pantry is open,

and you can use that steel
in any technique you want

to make your blades.

Our clock
will be moving forward,

and it's a race to the finish.

And today, gentlemen,
your finish line

is to get your blade
to fit inside this sheath.

The first smith who
is able to recreate this blade

You will be
rewarded with an extra

30 minutes in the
second round of competition.

Now, the runner-up
will get an extra 15 minutes,

and the last smith will
have 15 minutes deducted

from their second round time.

- The first guy
that gets his knife in the case

gets an extra 30 minutes
for the handle.

I wanna be that first guy.

- Now, for those of you
who do join us

in round two of the competition,

you will finish your blades
by adding handles to them,

turning them into
fully functioning weapons,

at which point, our judges
will take over and test them

for strength and durability
in a gunpowder barrel chop

and check your edge
retention in a mailbag slice.

Gentlemen, you have
three hours on the clock.

So good luck.
Stay sharp.

Your time starts now.

And they're off to the races.

The smiths have the choice
of any steel they want,

but they have to recreate the
Bowie knife we have on display.

- What's great about this
challenge is it's not just

about making a knife.

It's finding the material
to make the quickest

and the best knife
you can turn in.

So it's a lot about speed.

- So Eric's picked up steel.

He's got 1095, 15N20,
so he's gonna make

some Damascus.

- That Western-style Bowie
is a very wide knife,

so I know
if I stack up enough steel,

I'll have plenty of steel
to get the width of my blade.

I feel good.
I took way more steel

than what I needed.

I don't know if I'm gonna be
the one to get to 30 minutes.

As long as I complete it,
that's all I'm worried about.

- Nathan looks like he just
grabbed a bar of W1.

- Yeah, those bars are about
5 inches, by one by one.

- Right.
- It's enough steel.

- The parameters are probably
what's gonna hang me up.

Let's not get flashy.
Just keep it simple.

I'm not gonna go in worrying
about gettin' it

sheathed first or anything.
I'm in it to win it.

But I'm in it to,
like, just get it done.

Yeehaw!

- I go to the pantry
to pick out steel,

and I'm scared to death.

I think I'm gonna do a canister.

- If he is going for a canister,

he's gonna be taking
some extra steps.

- I think there
is no way in hell

I'm gonna be able
to finish a canister Damascus

front to back in three hours.

- All right,
he put the powder back

and got a piece of that W1.

- Anytime you go with a
mono steel versus a Damascus,

you're always gonna sacrifice
a little bit of beauty.

But speed is still
a part of this challenge.

Yeehaw!

- I go for layered Damascus,
15N20 and 1095.

I really feel like the Damascus

is gonna set me apart.

- Give it to the smiths
for doing layered Damascus.

Steppin' up the game,
that's great.

- Come on, baby.

The hardest part
about the challenge,

I think, is the clock.

This is quick.
This is intense.

- All right, guys,
30 minutes have elapsed

in this competition!

- I like what
Eric's doing, though.

He's taking small bites,
but fast bites.

- Yep.

- I take a few heats,
and my billet is solid.

- He's goin' fast,
and he's flipping it

and hitting it for both sides.

- I don't wanna think I'm
gonna win the round

right out the gates like this.

Just 'cause you're
being the fastest,

doesn't mean it's the best.

- So I got my steel up to heat,

and I'm just gonna get started

gettin' it drawn out
a little bit.

- Looks like a good color.

But if Nathan doesn't
start fullering that

in his next heat,
he might be in trouble.

He...

Was Nathan wearing a
cowboy hat before?

- No, I think he just stole it
off the wall.

- I'm in a daze.

I'm just like,
"I just need to move steel,"

and after my second pass,

I just started to notice
that it's gettin' longer,

but it's not getting wider.

I'm trying to kind of
spread it a little bit.

It's getting more thin
than I'm comfortable with.

So I'm lookin' at the clock,
and I'm just like,

"Oh crap, man."
It's now or never

if you're gonna start over.

- Nathan's come back
to the metal supply.

He's grabbed a new bar W1.

Total restart.

- Hopefully he learned
from the first piece of steel,

"Wait, I need
to do this instead."

- How you doin', LJ?

- Oh... gettin' a little...

A little anxious.

- Just make your knife.
- Yes, sir.

Just makin' a knife.

The round stock that I've got,
I need to press it flat,

get it as wide
into the parameters as I can.

So you gotta just beat
the lights out of it.

I'm close, but no cigar.

It's a real test to get this
thing where I need it to be.

This is a workout.

- I grabbed my Damascus,
and I'm ready to go.

It starts moving like putty,

and then...

The problem I'm seeing
on my forge welds...

They're not sticking
like I wanted them to.

- To me, it kind of
looked like the back opened up.

I've seen too many people
beat a dead horse,

and so I decide
it's time to start over,

and I go back to the pantry.

- Greg looks like he's
completely startin' over

as well.
- Right.

- They do realize they only
have three hours, right?

- I grabbed a bar of 1095,

and I know that I can make
the parameters with this steel.

- Eric is coming up
to the example to check it.

I think he's
pretty damn close as it is.

- I got my blade
forged to a good profile...

Gotta move over to the grinder.

I look around and realize that

I'm the only smith
profiling my knife.

I may be ahead right now,

but that's
no reason to slow down.

- Bladesmiths, we are halfway
through the competition!

- So I'm lookin'
at the example blade,

and I'm like,
"That's a San Mai."

- I've never done San Mai.

Like, why not do it
for the first time?

What could go wrong?

- But even if he does San Mai,

he's still learning to draw
it longer and not wider.

It's the same thing.

- Gotta add more steel.

It gives him a better chance

to stretch that out
and fuller it.

- I get the W1.

I'm sandwiching it
between the two pieces

of angle that I've cut,

and I take it over to the press.

I am just ecstatic
that it doesn't just, like,

flop out on me.

I was like,
"Holy. It worked."

Now I know my welds are set.

Then I just start
working on making something

that looks like a blade.

- With four forges going,
I heard the saying

that no matter how hot you
think it is, it's even hotter.

It is ridiculously hot
in the shop.

- LJ's not looking good.

- He's looking very fatigued.

- Sorry to be the guy.

- What's going on?
- I'm cramping up.

My body forces me to stop.

- Okay, why don't we take a
step outside for a few minutes?

- Guys, LJ's stepping off
The Forge floor with the medic.

- Never had anything
like this before.

I absolutely do not
wanna walk away from this.

I don't wanna stop.

But sometimes,
you don't have a choice.

- What's going on?
- I'm cramping up.

- Guys, LJ's not looking so hot.

He's got massive hand cramps.

He's stepping off
The Forge floor

with the medic.

- It's the craziest thing.

I'm not going home till the
judges send me home.

I'm gonna finish this
one way or the other.

- LJ's back.
- Always a good sign.

- That's a smith with zero quit.

- I just feel that I'm behind.

But I just refuse to quit.

- Talk about Greg, he
actually did really fast work

after that restart.

- Now I'm just worried
about being first.

Heavenly Father, Lord,
let this quench go good.

- Greg just quenched.
- Holy smoke!

Greg is the first one to quench.

- It's just a shy bit over.

So we're gonna
take a little bit off.

- Bladesmiths, there's
one hour left in this round!

- So I look over,
and I see Greg quench.

But I'm not concerned of
being the first one

in the sheath...
I just wanna make sure

I'm not the last.

I'm confident going
into this quench.

But you never know
what's gonna happen.

- There goes Eric.

- All right, here we go.
Eric's into the oil.

He's got a blade that
is very close to the example.

At this point,
I'm feeling pretty confident.

All I have to do is
get it cleaned up and etched.

- Never quenched
a San Mai billet.

I hope it doesn't blow apart
on me.

- Holy... Nathan just quenched.

- I pull it out of the
straightening jig,

and it's, like, straight.

I wanna shed, like, a tear.

Holy crap. I did it.

- I feel that I'm behind.

But I actually want to forge

as much of this blade as I can.

Trying to make sure
all the parameters

are as close as I can get it.

- LJ has his
way longer than the example

and not nearly wide enough.

- I think
I'm right there on the money.

- Boom! LJ quenched.

We got four quenched blades.

- No cracks.
I heard no tinks in the oil.

So I'm just
as tickled as I can be.

- It seems like we might
have a sheath race going on.

Greg and Eric both have done
a lot of work on their blades.

One of them is gonna
be the first in the sheath

getting their 30 minutes
in the second round.

It's rough.
It's got some forge marks.

It's got some forge scale.

But I'm ready to give it a try.

- Here we go, and kablam!

First one.

- All right, Greg.
You're the first one

in the sheath.

- I am the fastest blade
in the west.

- I wanna make sure
I get my blade etched

'cause I put all the work
to make it out of Damascus.

I think my blade's ready
for the sheath.

But I make sure
to check my measurements.

- Eric's coming back
to do another final check.

- Looking pretty good.

- Whoa... bam!

All right. There's two.

- Nathan's pulling up
from behind.

You know I'm thinking, so,

"I've got to get to that
sheath before he does."

- Being in sheath doesn't mean
you're automatically going

in the next round.

LJ is on his way up
to the sheath right now, guys.

Oh, this will be amazing.

LJ, you powered through.
You got it done, man!

Well done!

- I'm ecstatic.

- Now Nathan can take his time
to get it dialed in perfectly.

10 minutes left!

- I know I'm not
the fastest blade in the West.

I'm not even the fastest blade

in the Hammered Billet Saloon.

So I'm just gonna try
to make it as good as I can

in the time I got left.

- We've got four blades
completed and sheathed!

Well done!

- I'm looking at the blade,
and I'm thinking, like,

"Man, it doesn't matter
if I lose 15 minutes.

Like, I could lose
the whole next round.

- Bladesmiths, congratulations.

You managed to take
steels of your choice

and turn them
into Mexican Bowies.

Greg, you were
the first in the sheath.

Please present your work.

- Good job on this, Greg.

Congratulations getting your
blade in the sheath first.

The steel looks fine.

It's a very extreme taper

coming up through here.

But it's definitely
something fixable.

Obviously, if you move
into the next round,

you need to do something
about that mass on this tang.

But your profile looks
pretty close to our example.

It's a nice job.
- Thank you.

- Eric,
please present your work.

- This is beautiful work
right here.

You brought your sample right
up to it,

and you made all the changes
so it's almost exact.

Right now, the way it stands,

it's a good looking blade.
- Thank you.

- LJ, please present
your work, sir.

- All right, LJ, good,
solid job on the blade.

Your profile, though...

Your tip's a bit
on the high end.

I know you were having trouble
moving that steel around

and getting that width.

If you move to the next round,
I'd drop that tip down.

But you pulled through it,
so good job.

- Yes, sir.

Nathan.
You ready?

I'm your Huckleberry.

Please present your work.

- All right, Nathan, first off,

really good choice
to start over.

Your San Mai looks solid
and welded up.

There's a lot
of material here to work with.

Your blade's
already dead straight.

If you move forward,
compare it to the actual blade.

There's a lot
of adjustments to do here.

But all in all, really
nice job getting this done.

- Thank you, sir.

- Bladesmiths, as you know,
only three of you can join us

in the second round
of this competition.

The bladesmith
leaving The Forge is...

LJ.

Unfortunately,
your blade didn't make the cut,

and Dave's gonna tell you why.

- LJ, first off,
you got no quit in you.

It was great watching you work.

This comes down to that your
blade is furthest away

from our finished shape
than the other blades,

and that's the reason
we're letting you go.

- LJ, you're a talented smith.
You've got zero quit in you.

But unfortunately,
at this point in time,

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

and step off The Forge floor.

- Thank you for not giving up.
Good job.

- It always feels bad
when you lose.

But I've had one
of the best times of my life.

It's a learning
and growing experience.

But I'll go home,
I'll lick my wounds,

and I'll be stronger tomorrow.

- Bladesmiths, congratulations.

The three of you are
joining us in the second round

of this competition, where
you're gonna fix any issues

that you have from the first
round, as well as add handles

to your blades, turning them
into fully functioning

Mexican Bowie knives.

Now, we want a recreation
of this blade.

So you'll be adding staghorn
handles to your blades,

as well as a S-guard.

Now, Greg,
you sheathed your blade first,

so you got yourself an extra
30 minutes for the second round

of competition.

Now, Eric, you have two hours
and fifteen minutes.

Nathan, you only have an hour
and 45 minutes to complete

your Mexican Bowie knife.

Now, after this round
is complete, gentlemen,

you'll turn your blades over
to the judges,

and they'll check
for strength and durability

in a gun powder barrel chop,

and then check your edge
retention in a mailbag slice.

Now, we're gonna do this
in a staggered start.

So good luck.
Greg, your time starts now.

- It is wonderful
to have first choice

at the pantry.

I mean, this is weird watching
one competitor go at it

and two of them
sitting down like we are.

Don't just sit around.
That's our job.

Look pretty.

- I knew that I was going
to need that extra time.

I have got to put the tang
on a weight loss program.

- All right, Eric...
Coming up on two hours

and fifteen minutes.

Your time starts now.

- Still got it, bro.

I made sure the piece I choose
is as close to the original

so I don't have
to do as much shaping

and moving of material.

- All right, Eric
just grabbed the guard stock.

He grabbed penstock, and
he's already to the grinder.

- The first thing
I do is take my knife

and start cleaning it up.

I know I still have a lot to do,

and I'm not gonna
waste any time.

- All right, Nathan.
Time to wake up.

You got an hour and 45 minutes!

Good luck, man.
Your time starts now!

- So as soon as
the clock starts, I'm like,

"Dude, I gotta
go see what's left."

- He's already way
behind both the other smiths.

If you guys were Nathan,
what would you be doing

right off the bat?
- Get your stuff,

and start griding that blade.

- Going into this round, man,

I've got to get my tang
kind of centered.

Then I'm gonna try and take
some of the meat off of it.

I'm feeling
pretty confident coming in.

But every second's gonna count.

- After the tang,
it's the guard.

I heat the guard in a post vise,

twist it a half turn
on both ends so that the bars

will be at a 90-degree angle
from the blade.

That's more what I want.

I am pleased with my S shape.

With more time, I can make it

a lot more
aesthetically pleasing,

but it fits the parameters.

- Bladesmiths,
you have an hour and a half

left before testing.

- The guard is the most
ornate part of this knife.

So making sure
it matches as best that it can

is kind of my main concern.

First thing I need to do
is rough cut out my shape.

- So Eric
is doing the exact same thing

he did in the first round...
He came up to the example

and measured every single
dimension of the guard.

So his is gonna be intricate.

- Oh, that'd be great.

- Next thing I need to do,
twist my steel.

Two torches may be overkill,

but it's gonna
make the process a lot faster.

It's looking rough,
but the profile's there.

Now all I gotta do is refine it.

- So Nathan... although
he came into the second round

seemingly way behind,
he's catching up pretty quick.

- I've just got this flat piece

that's fitted and slotted.

I know I can bend this mild
steel to make an S-shape.

I know it's not gonna be
as pretty as my competitors,

but time is of the essence,

and I'm just hoping
for the best.

- All right, bladesmiths,
you guys are down

to the final hour!

- At this point,
the clock is against me.

I have to get this together.

I've to drill the pinhole
in the tang

to have a mechanical connection.

And it doesn't take.

This is not a good time
for this to be happening.

I can ruin 20 drill bits,

and it's not gonna go
through that 1/2 inch tang

of hardened steel.

This is not ideal at all.

- Greg's got his blade
clamped in the vise over here,

and he was trying to drill
through the tang.

It wasn't going through, so
now he's got the hot wrench...

Gonna soften that tang up.

- There's no time
for new bumps or anything.

It's time to act.

I slap another bit
into the drill press.

Whoo-hoo!

It just beached through
like butter,

and it's off to the races.

Everything's sliding down.

Works like a charm.

Time to get the thing sanded.

- Looking good.

Finally, I get the guard
to fit the tang,

and now it's time to move on
to the antler handle.

- So Eric's drilling in the
tang hole in his staghorn.

- Whoo!

I get everything glued together.

It all seems to be fitting
nice and tight.

I need to get an edge
on this knife.

- Nathan using a lot of epoxy.

- Epoxy's just going everywhere.

You wanna know where
Nathan went,

just follow the epoxy.

I don't wanna glue up my beard.

- Bladesmiths,
you have five minutes left!

- I'm, like, super frustrated,
and I'm starting to flip.

All right, just... stay calm.

Obviously, there's a ton
of finish and finer details

that could've
been done on my blade.

But, you know, I'm just stoked
that I didn't give up.

- Five, four,

three, two, one.

Bladesmiths,
turn off your machines!

Put down your tools!

The second round of this
competition is over!

- Don't stare
at it too long, guys.

It'll blind you.

- I feel pretty solid
about my edge.

But I'm just worried about
J. Neilson having my blade.

He has very intimidating grunts

every time he chops something.

I'm scared.

- Bladesmiths,
welcome to our strength test:

our gunpowder barrel
stab and chop.

Greg, you're up first.
You ready to go?

- Oh, absolutely.
- All right. Let's do it.

- The test is incredibly
difficult.

Hitting a knife
into metal and wood...

Anything could happen
to that blade.

If that heat treat wasn't
perfect, it's gonna fail.

All right, Greg. Good job here.

Your edge is still fine.

Nothing bent.

But you lost some epoxy
right in here

where you're trying
to fill that out.

But everything's still tight.
Good job.

- Thank you.
- How you feeling, Eric?

It's always fun
for the second guy.

- I'm ready.
- All right, let's do it.

- I'm nervous to see J. beat
my knife against a barrel.

I don't expect my knife
to break.

But you never know what's gonna
happen during testing.

Nice job, Eric.

The edge is still sharp.

Nothing happened
to that or the tip.

You got everything comfortable.

Your dimensions
are just right for my hand.

This is probably the closest
to a completed replica

of something
we presented to date.

Nice job.
- Thank you.

- What do you think, Nathan?
- I... I'm your Huckleberry?

You are for now.

- If anything was to give
on my blade,

it's gonna be the handle.

I know it's not winning
a beauty contest.

But I hope that my handle
sticks together.

We'll see how it goes.

- If anything was to give
on my blade,

it's gonna be the handle.

But I hope that my handle
sticks together.

Take a breath, Nathan.
You survived.

You got...

one small rolling in my nail on.

Now your handle...

- Your blade's here,
and your handle's

kind of drifting this way.
- Mm-hmm.

- But the big problem I see is,
now your guard is loose.

But it survived the test.

Great job.
- Thanks, man.

- Howdy, bladesmiths.

Now it's time to find out just
how sharp your weapons are.

This is the sharpness test:
the mailbag stab and slice.

Now it's time to go postal.

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

- Yes, sir. Absolutely.

All right, let's do it.

All right, Greg.

You have a very obtuse grind
on your blade here,

and stabbing,
you can feel the resistance.

But on the slashes,
it cuts cleanly.

Overall, it'll cut.
- Mm, thank you.

- All right, Eric.
Your turn, sir.

You ready?
- Absolutely.

- Giddy-up.

All right, Eric.
Your edge and even the bevels

that you have here for
thrusting met no resistance.

It cuts nicely.

It's got a great bounce to this,

and overall, sir...
it will cut.

Thank you.

All right, Nathan.
Your turn, sir.

You ready?
- Yeehaw.

- Let's do that.

Oh.

- All right, Nathan, let's talk
about your blade here.

It stabbed and cut easily
on this mailbag.

But your handle is still loose.

Overall, sir... it will cut.

- Yeehaw.

Well...

Bladesmiths, you all
came through with blades

that performed
very well on our tests.

But as you know, only two
of you can move forward,

staying in contention
for a check for $10,000

and the title
of "Forged in Fire Champion,"

moving on into the final round.

The bladesmith
leaving The Forge is...

Nathan.

Unfortunately, your blade
didn't make the cut,

and J.'s gonna tell you why.

- All right, Nathan.

You did a great job,

especially with
the amount of time you had,

and you obviously made
something that could cut.

But during the strength test,
you picked up a bit of a chip

on the edge,
and your guard came loose.

That's why we're letting you go.

- I understand.

- Well, Nathan, you brought
a lot of life into The Forge.

We want to say
thank you for coming out here

and letting us watch you work.

But unfortunately, at this time,

I'm gonna have to ask
you to please step off

The Forge floor.

- I really appreciate it, guys.
This is super rad.

- Thank you.
- Good work.

- I think I won in a competition

against that voice
that tells you not to try,

and it tells you to give up.

I wish that my blade
could've been more refined...

Obviously, more pretty.

But I made my first
San Mai blade weld stuck,

and it cut
like a freaking razor,

and I would do it all again,
for sure.

- But Greg, Eric, gentlemen,
congratulations.

You're moving forward
to the third and final round

of this competition.

You get four days
at your home forges

to build another iconic weapon
from the Wild West.

Gentlemen,
we want you to build this.

This is the vaquero machete.

- The vaquero machete
became wildly popular

with the original cowboys
of the Southwest

during the 20th century.

Featuring a thin,
slightly curved blade,

the weapon was much lighter
and easier to carry

than the larger machetes
previously used

by the cowboys,
making it ideal to deliver

damaging slashes and chops
on everything

from brush to enemies
on the great frontier.

The rich history and culture
of the cowboys

who carried this weapon
can be found on display

at the Bullock Museum
in Austin, Texas.

- Now, your blades
need to be curved

and have a length
between 24 and 26 inches.

They need to have a single edge.

Need to have an S guard,
a stacked leather handle,

and an eagle head
or a horse head pommel.

- I'm glad that it's not some
sort of war hammer or axe.

But still, this thing's gonna
be complicated to make.

- Gentlemen, we want to see
your very best,

most beautiful blades
come back, so good luck.

We will see you in four days.

- I'm back here at my home forge

to make the vaquero machete.

I decided to go with
a mono steel blade of 1080.

It's a tough, springy steel
that's very forgiving.

All right, she is cooking.

Whoo! Like a June bride.

Okay.

Straight blade.

Everything's coming out nicely.

I'm going to start on the pommel

and the guard in the morning.

Just like it's supposed to.

- Today is day one.

We're here in my home forge

in Harmony, Pennsylvania.

Gonna get the forge heating up.

My game plan is
to start with Damascus.

We're using a combination
of 1084 and 15N20.

My goal is get the blade
forged out on day one.

We're gonna start out
with 20 pieces.

Shooting for a 60-to 70-layer
in the end.

So I got my billets loaded up
and in the forge.

So today, I'll be able to forge
a 60-layer Damascus blade.

Feel good
about the progress I made.

Got to where I wanted to be.

So far, it's looking good.

- It's the morning of day two.

We're gonna start on the S guard

and the horse head pommel.

The gas foundry
is what I'm gonna be making

the guard and the pommel out of.

You carve the exact thing
you want to cast out of foam.

This is what it will look like
when we get done.

Then you pack it
in green sand...

Here we go. You ready?

And as you pour
the molten metal on it,

it evaporates the foam

and leaves you with the shape
that you desired.

Nope. Nope.

100% failure.

Definitely not
a successful pour.

There was too much moisture
in the mold.

And it didn't cast all the way.

Back to the drawing board.

Oh.

- My biggest thing today
is to get

my horse head pommel done.

Nope.

Definitely not
a successful pour.

There was too much moisture
in the mold.

And it didn't cast all the way.

Let's do this.

I'm gonna add more water
to my sand

and give it a second shot.

That was good, guys.

That's exciting.

After a little bit of sanding,
it'll look great.

- Today is day three.

So last night, got it quenched
and in temper.

For today,
thinking about starting work

on the pommel.

And I knew my dad and
my brother were out hunting

with the hawks;
I had them stop over so that

I could get a nice look
at a 3-D bird.

My dad's been a falconer
since before I was born,

so I've always had hawks
my entire life.

It's very lucky that
I'm able to incorporate this

'cause that way I can do
a direct comparison.

I've made good progress today
on my blade.

But still, you never know
what's gonna happen.

That was purposeful.
It was a test. Strength test.

- It's the last day
of the home forge.

Today we're gonna start off

by sculpting
a horse head pommel,

and then we're gonna get to the
fit and finish of the blade.

Clear out, birds. Come on.
Everybody out.

My turkeys came in
to offer their two cents.

But turkey logic just
isn't what it used to be.

Okay.

We have at least one good cast.

I bet we can clean that one up
to make it work.

The one thing you need
to worry about

with this kind of handle

is not getting your pieces
glued well enough.

If you don't have your handles
glued well enough,

it's not gonna make
a concentric handle.

Oh, this leather's really thick.

I am nervous
going back into the forge.

My competition's gonna be good.

But at the end of the day,
he's gonna bring his best.

I brought my best.
We'll see what happens.

Think that'll work.

- Today's the beginning
of day four.

I'm getting ready to go
into gluing the handle.

We wanna make sure we get
everything glued up

in one swift motion.

That way,
we can get a clamp on this.

We can get everything
compressed.

Now the epoxy's all cured,

I'm gonna start shaping
the handle.

And then once I get
all the cleanup finished,

pretty much all I have to do
is add an edge,

and then we'll be done.

And I'm really proud
of how this looks.

- Well, gentlemen,
welcome back to The Forge.

It's good to see you.

We gave you four days
to put together

your very best versions
of the vaquero machete.

I gotta say, we are impressed.

But before we put them
to the test

to find out which one of you
is coming out on top

of this competition,
we wanna hear about them.

Now, Greg, how'd it go for you?

- Oh, it went wonderful.

The machete's built out
of 1080 high-carbon steel.

The pommel and the guard are
foam casted

with a leather stacked grip
and turquoise accents.

- Outstanding.
Eric, how about you?

- Everything went really well
for me.

I went with 70 layers
of 1084 and 15N20

for the Damascus.

Did brass
for the eagle head pommel

and the S guard.

And did some stacked leather
for the handle.

- Sweet.

All right, gentlemen,
in order to find out

which one of you is coming out
on top of this competition,

getting that check

and the title
of "Forge in Fire" champion,

we need to put your blades
through a series of tests.

And for that,
I'm gonna give you to Doug.

- Howdy, partners.

Welcome to the KEAL test.

Your vaquero machetes
look beautiful.

But how lethal are they?

To find that out,
I'm gonna take their machetes

and deliver some lethal blows
on this pig carcass.

Greg, you feel lucky?

- Oh, very lucky.
- All right, let's do this.

- I'm almost giddy
with excitement

because there is a big pig.

My machete ought to be
a wonderful pork slicer.

- All right, Greg,

the leather wrapping that you
have here is nice and smooth.

The handle is ovoid.

The one thing, though,
that's just a lot of handle.

And because you have
a smooth handle right here,

couple of times,
my hand just slid down.

But your edges are sharp.

Those are razor-sharp cuts.

Overall, sir, it will KEAL.

- Ooh, thank you, Doug.

- Eric, your turn.
Are you ready?

- Let's do it.
- Let's do this.

- I'm stressing out
over what my blade's gonna do.

And after seeing
what Greg's just did,

I'm even more nervous.

- All right, Eric, let's talk
about your vaquero machete here.

What I like about it is that
it just my hand perfectly.

So it's locked in there.

Now your edge,
that's a chevron right there

all the way up.

Those are very sharp, deep cuts,

even on thrusting.

Overall, sir, it will KEAL.

- Good to hear.

- Hola, vaqueros.
Welcome to our strength test.

The fence board and skull chop.

- All right, Greg,
you're up first, you ready?

- Yes, sir.

I see that buffalo head,
and I nearly pee.

Buffalo heads are thick.
They are solid.

They use those things to hit
each other all the time with.

I don't know about my little
blade hitting it that hard.

- I see that buffalo head,
and I nearly pee.

Buffalo heads are thick.
They are solid.

I don't know about my little
blade hitting it that hard.

- So Greg, right off,
blade held up beautifully.

This thing is just as sharp
as when I started.

Feels like a great fighter
to me.

Only complaint I have
is that long handle.

But other than that, the
artistry is really well done.

That's a joy to use.
Nicely done.

- Thank you.

- Eric, you ready?
- Let's do it.

- All right.

- Bleep.

- All right, so first off, Eric,

very different grind
on this edge

with that secondary bevel.

But it's wicked sharp,
and it's still sharp.

Held up fine.
Didn't lose any blade at all.

No rolls, no chips, nothing.

It's still as straight
as when I started.

Good job.
- Awesome, thank you.

- Bladesmiths,
welcome to the sharpness test.

The gunslinger slice.

- Yeehaw.

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

- Absolutely.

- All right, giddy up!

All right, Greg.

Nicely done.

Those are very sharp, clean cuts

on, I'd say, at least
three layers of clothing.

Your weapon, it will cut.

- Thank you.

- Eric, your turn, sir. Ready?

- Let's do it.
- Let's do this.

All right, Eric.

The edges are sharp enough
to cut through all layers

and expose some of the blood.

Overall, sir, your weapon
will cut.

- Thank you.

- All right, gentlemen.

Well, I gotta say,
both of you impressed us

from the very beginning
of this competition.

The first two rounds,
you guys crushed it.

But this competition,
as you know,

only one of you can leave here
as a "Forged in Fire" champion

and receive that check
for $10,000.

The "Forged in Fire"
champion is...

Eric.
Congratulations, you did it.

Now, Greg,
you have a ton to be proud of.

That is an unbelievably
beautiful piece.

But you lost by just this much,
and Dave's gonna tell you why.

- Greg, the artistry
you brought to that blade

is fantastic.
That pommel is beautiful.

This really came down
to the scale of that handle.

And that's why
we're sending you home.

- Thank you.

- Well, Greg, I hope you had
as much fun working here

as we had watching you.

That is an unbelievably
stunning piece.

But unfortunately, your time
in the competition has ended.

I want to say
thank you for coming.

But at this point in time,
I'm gonna have to ask you

to please step off
The Forge floor.

- Thank you.

Take care, man.

I have no shame coming
in second to this young man.

The check would have been nice.

The title would have been nicer.

But remember, I'm still
the fastest blade in the West.

- Well, Eric, you are the
"Forged in Fire" champion,

and you're receiving a check
for $10,000.

Congratulations.
- Thank you.

- How are you feeling?
- Crazy.

Never thought I'd be here
at this young.

I don't even know how to react.
It feels surreal.

From start to finish,

it's been a crazy,
crazy competition.

And my uncle, he was probably
my biggest drive

to win it.
Uncle Chuck, this is for you.

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