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  • Jerad, Lee, congratulations.

  • You guys have made it into the next phase

  • of this selection process.

  • What you're fighting for is the Navy Anvil

  • at the Battle of the Branches final competition

  • and a chance to win $50,000.

  • And now we're sending you back to your home forges

  • to recreate this military weapon from history--

  • the US Naval officer sword.

  • Awesome.

  • You'll have four days at your home forages

  • in which to complete all these parameters.

  • At the end of those four days, you'll

  • return and present your blades to our panel of expert judges.

  • After they've expertly tested them, they'll push one of you

  • forward into the Battle of the Branches competition.

  • Good luck, bladesmiths.

  • We'll see you in four days.

  • [sighs]

  • [music playing]

  • Today is day one.

  • And today, I'm working on forging

  • out the basic shape of the sword,

  • and maybe get to heat treat it.

  • The Navy way as slow is smooth.

  • Start slow, and it will turn into speed and perfection

  • later on.

  • I got my sword shaped out.

  • And I'm ready for a heat treat.

  • End of day one, no cracks.

  • I'm feeling pretty good.

  • I'm sitting well right now.

  • Yup.

  • That is sexy.

  • All right.

  • First thing I'm going to do today

  • is use my rotary tool and hand grind in my puller.

  • [grinding]

  • For a hand puller, you can't ask for much better.

  • Blade's ready to be quenched.

  • The one thing you always think about is, don't snap.

  • This is the moment.

  • Don't have a warp.

  • Snaps are fatal.

  • Warps are critical, but can be fixed.

  • [music playing]

  • Pull it out.

  • Uh oh.

  • It's hard.

  • But it's got a bow.

  • To the jig.

  • I have to get it in my straightening jig to see

  • if we get that pulled out.

  • Let's hope it straightened it.

  • If not, we go through that whole thing again.

  • Pick it up.

  • Look down it.

  • Bam.

  • We've got a straight blade.

  • 10 minutes, Pigs Smiths.

  • You have 10 tiny minutes.

  • [laughs]

  • So, as of right now, my plan is to get some sheet steel,

  • use that for the majority of the leaf guard,

  • and then getting some steel for the knuckle guard

  • and braiding it.

  • Kind of give it a nautical Naval theme to it.

  • Try and make it look like some rope or line.

  • This wire's bulking up way more than I thought it would be.

  • I'm trying to braid this thing.

  • It's not moving the way I want it to.

  • I didn't want nearly as many gaps as this.

  • So I'm starting to get a little frustrated.

  • I still have a whole lot to do.

  • But, at the end of the day, I'm treating this

  • as if this is a $50,000 sword.

  • So I'm going to put every ounce energy I have into it.

  • I decided I'm just going to stick

  • this in the vise and start twisting

  • and until it looks like rope.

  • All right.

  • First things first.

  • Put the coffee down.

  • Pick the sword up.

  • Tempered last night, and the warp that I thought I had fixed

  • came back in the temper overnight.

  • Right down the edge.

  • Right down that spine.

  • I have to get this fixed before I move on with the sword.

  • [sighs]

  • To get this warp out, I'm going to have to pin it, heat up

  • the spine, then let it relax.

  • And, hopefully, the warp will come out.

  • A little tap.

  • But I can live with that.

  • It don't rock.

  • Finally get this warp out.

  • Still hard.

  • It's time to move on to the handle material.

  • I set up the Micarta handles by cutting them in rough shape

  • to fit the handle, drill the holes.

  • (SINGING) Like that.

  • Next, I needed to get the pommel so when

  • I do make the guard and knuckle bow, I know where to end it.

  • So I need the pommel next.

  • It's pretty blade heavy.

  • And it's going to need a big chunk of brass

  • to be able to balance that out.

  • Done.

  • [laughs]

  • All right, sailors.

  • Your weapons looks beautiful.

  • But it's time to find out if they're wall hangers

  • or they're actually something you could use to kill.

  • Jerad, you're up first.

  • You ready for this?

  • I'm ready.

  • Let's do this.

  • [music playing]

  • [laughs]

  • All right, Jerad.

  • The balance you have here feels good in the hand.

  • Now, your edge is very sharp.

  • As you can see, with every cut, it cuts deep.

  • For every thrust, all the way through and true.

  • Overall, sir, your weapon will kill.

  • Thank you.

  • Good job.

  • All right, Lee.

  • It's your turn.

  • You ready?

  • Yes, sir.

  • Let's do this.

  • That's a lot of hog to go through with a skinny blade.

  • I'm pretty nervous.

  • [music playing]

  • (WHISPERS) Good job.

  • (WHISPERS) Thanks.

  • All right, Lee.

  • The handle construction is comfortable.

  • Your edge, not one single glint or rolling.

  • Your tip punctures and cuts on the way out.

  • And overall, sir, it will kill.

  • Yes.

  • All right, gentlemen.

  • It's time for the strength test.

  • The dreaded flex test.

  • To test the strength of your blade,

  • I'll be bending it in both directions

  • up to that red point.

  • Jerad, you ready for this?

  • I guess.

  • OK.

  • [exhales heavily]

  • [music playing]

  • Ooh.

  • [laughs]

  • [exhales heavily]

  • I'm impressed.

  • Your blade is just as straight as when we started the test.

  • That's a really nice heat treat.

  • Thank you.

  • Holding your sword, you can shorten that handle

  • just a little bit scale-wise.

  • But, at the same time, it winds up being fairly comfortable.

  • Nicely done.

  • Thanks.

  • All right, Lee.

  • You're up.

  • You ready for this?

  • Yes, sir.

  • OK.

  • [music playing]

  • The longest five seconds of my life.

  • [music playing]

  • [exhales heavily]

  • Nice job, Lee.

  • The blade is still the same shape it started in.

  • That's impressive.

  • Thank you, sir.

  • Really good.

  • All right, gentlemen.

  • It's time for the sharpness test.

  • We call this the Fish Slice.

  • We're going to be lowering those fish down.

  • I'm just going to start cutting.

  • I'm going to keep cutting until I run out of fish.

  • All right, Jerad, you're up first.

  • Are you ready?

  • I'm ready.

  • OK.

  • [music playing]

  • [laughs] This is why I love sabers.

  • They are just so much fun to cut with.

  • Just passing right through the fish beautifully.

  • Your handle construction might be a little bit wide.

  • But it's comfortable and it stays in my hand.

  • I think you did a great job.

  • Thank you.

  • Lee, you're ready?

  • [sighs] Yes, sir.

  • OK.

  • [music playing]

  • All right, Lee.

  • Cuts beautifully.

  • I mean, the edge on this is wonderful.

  • The saber's definitely sharp, and a great balance.

  • Nicely done.

  • Thank you, sir.

  • Jerad and I are neck and neck.

  • I mean, both blades performed great.

  • Jerad, Lee, only one of you can move forward

  • and that smith is Lee.

  • Congratulations.

  • You'll be moving forward to represent

  • the United States Navy in the Battle of the Branches

  • final competition.

  • Congratulations. Good job.

  • Thank you.

  • Jerad, unfortunately, your blade didn't make the cut,

  • and David Baker is going to tell you why.

  • Jerad, you brought us an effective cutting sword.

  • But this came down to the basic details

  • of aesthetics and the way that weapons felt in my hand.

  • I understand.

  • Well, Jerad, come on forward, brother.

  • Good job, man.

  • This competition was such a learning experience for me.

  • Made a lot of good friends.

  • I had a great time.

  • Give them hell.

  • Good job, shipmate.

  • I didn't win.

  • But I did two very awesome swords.

  • Lee, you did well.

  • Give them hell.

  • And take it home from the Navy.

  • Lee, congratulations.

  • You forged your way into this final competition

  • where you'll compete against the Air Force, Army, and Marine

  • Corps to bring home the title of Forged

  • in Fire Champion to the United States Navy.

  • And you'll also be competing to receive a check for $50,000.

  • You've done a fantastic job.

  • You're only halfway there.

  • And we'll see you real soon.

  • Good job.

  • Thank you, sir.

  • I just won.

  • Really?

  • Really?

  • Really?

  • Being able to represent the Navy is an honor.

  • I am totally ready to do this all over again.

  • And I'm going to tell you guys to bring your A

  • game because I'm bringing mine.

  • [music playing]

Jerad, Lee, congratulations.