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  • Bladesmiths, congratulations.

  • You've made it to the final round of this competition.

  • Now it's time to send you back to your home

  • forges to recreate this iconic weapon from history--

  • the boar sword.

  • Good luck.

  • We'll see you in four days.

  • Good job, man.

  • JONATHAN: So it's day one.

  • Excited to get to work on this boar sword.

  • Ready to knock it out.

  • I've never made anything this big.

  • It's going to be an interesting build.

  • Swinging this four-pound sledge is getting heavy already.

  • My game plan for today is to get at least half

  • of the sword force out.

  • I want to get those curves established.

  • It's definitely interesting hammering those waves in there,

  • because the blade will want to walk sideways.

  • And so having to bring it back to establish that edge to edge

  • straightness, it's difficult. I was hoping

  • to be able to get a little bit farther along than what I did,

  • but I think it's going pretty well.

  • Bit of a geometry dilemma here,

  • and I'm hitting the ceiling before I can

  • hit the blade on the grinder.

  • So I'm going to have to either take some extra whet out

  • here, make a cutout here.

  • I can't underestimate the size of this blade.

  • I got to be really careful while I'm trying to grind

  • it in my tiny little shop.

  • Perfect.

  • So after cutting away a bit of the table

  • and a bit of the roof, it seems to be working now.

  • So I just finished forging up the crossbar,

  • so it's time to quench.

  • If this goes well, I'll be set up really well for the rest

  • of this competition.

  • If it goes poorly, the opposite.

  • This crossbar is making it a lot more

  • difficult than I was anticipating

  • to get this whole blade hot.

  • Fortunately, it should be OK still.

  • Here we go.

  • [blowing]

  • [blade scraping]

  • That's the sound I wanted to hear.

  • Ha ha.

  • JONATHAN: Today, I hope to accomplish the heat treat.

  • This is the biggest thing I've ever heat treated.

  • I've got a forge that I'm borrowing from a buddy of mine.

  • It's a five-burner forge.

  • And it's normally laid down--

  • laying perpendicular.

  • I've got it standing up.

  • And so this is the first time I've used it in this fashion.

  • I hope it works for me.

  • I'm going to take my forge and set up underneath.

  • That way, I get a normal heat treat all the way

  • from the blade tip to the tank.

  • This heat treat process is the most critical part.

  • If you don't have the heat treat process down right,

  • then all you have is a blade-shaped object.

  • You know, it's not going to stay sharp.

  • So I've got to get this heat treat done.

  • It has to happen today.

  • It's go time.

  • If it doesn't go right, I don't know when I'm going to do.

  • [sighs] I do have a slight warp.

  • We're good.

  • I'm out of the woods, but still have some work to do.

  • So I was tempering last night with the torch

  • and screwed the pooch a little bit and got way too hot

  • on my blade.

  • So I've lost a lot of hardness, and I'm

  • going to have to re-quench.

  • I've never done a torch tempering before,

  • and I guess that's what I get for my lack of experience.

  • A second quench is just additional risk.

  • Every time you quench, there's a risk of extra warping,

  • of a crack, a broken blade.

  • It is quite a setback.

  • If this quench fails, I may be forced

  • to start over from scratch.

  • Here we go.

  • [blowing]

  • [blade scraping]

  • Definitely hard.

  • Disaster averted for now so long as I can get the tempering

  • right on my second try.

  • This time around, I'm going to be really slow, really careful.

  • And I've got my heat gun right here pointing at this blade

  • the whole time.

  • If it goes above 350 degrees, I'm

  • going to immediately pull the torch

  • and make sure that I don't overtemper this blade again.

  • The deed is done.

  • It should be a strong, hard blade now.

  • I'm going to move forward, put a handle on this,

  • polish it up, turn it into the judges.

  • JONATHAN: It's the start of the last day.

  • It's raining like cow piss on a flat rock outside,

  • so we're working on the handle and the pommel.

  • And just a little bit of clean up and sharpening,

  • and we're done.

  • Now I'm going to go into shaping.

  • That feels good and balanced right there.

  • The farther along I got in this build, the more confident

  • I became in the weapon.

  • I didn't have enough time to test it,

  • but I'm confident that it'll pass.

  • Ladies and gentlemen, the boar sword.

  • All right, bladesmiths, to test the lethality

  • of your boar swords, I will deliver thrusts

  • and cuts on this boar carcass.

  • Jon, you're first.

  • You ready for this?

  • Absolutely.

  • [blade impact sounds]

  • Yeah.

  • All right, Jon, first up, I like the balance.

  • I like that I can put two hands on it.

  • It's void enough to where I can hold on

  • and I can tell where the edge is.

  • And when we're pushing and thrusting as it's meant to be,

  • the tip is sharp enough to thrust all the way through.

  • Your edges, as you can see, are sharp enough to cut pieces

  • out of this boar carcass.

  • Overall, sir, it'll kill.

  • Thanks, sir.

  • Congrats.

  • Thanks, man.

  • All right, Isaac, your turn.

  • Are you ready for this?

  • Let's make some bacon.

  • [blade impact sounds]

  • [grunts]

  • All right, Isaac, first up, it's much lighter,

  • so it's easier to control when you're moving with a blade.

  • And as you can see, when I was thrusting in there,

  • the point you have here, the edges are very sharp.

  • It thrust all the way in.

  • And even when it hits bone, it's got a very good flex to it.

  • Did not pick up a bend.

  • Overall, sir, your boar sword will make the bacon and kill.

  • Thank you.

  • Gentlemen, it's time for the strength test--

  • the sheet metal stab.

  • Now, to test the strength and overall construction

  • of your blades, I'll be stabbing into the sheet metal.

  • But this test is not about what your blades do to that target.

  • It's about what that target does to your blades.

  • Jonathan, you're first.

  • You ready?

  • Absolutely.

  • [blade impact sounds]

  • All right Jonathan, your blade is still sharp pretty

  • much all the way to the tip.

  • Now, the tip did get flattened a little bit,

  • but that was a very, very acute tip that you had on there.

  • All in all, it's a comfortable weapon.

  • It certainly held up beautifully.

  • Nicely done.

  • Thank you.

  • All right, Isaac, are you ready for this?

  • As ready as I'm going to be.

  • [blade impact sounds]

  • There is definitely a significant bend.

  • All right, there's a good flex in your blade, which

  • we saw in an earlier test.

  • But when you quenched this blade,

  • I'm assuming right in here somewhere

  • was where that quench stopped.

  • So this is not really solid right here.

  • You did lose your tip up here, but your edges held up.

  • It's still sharp.