Bladesmiths, congratulations.

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

Now it's time for you to go back to your home

forges and recreate this iconic weapon from history--

a Bhuj.

Good luck, bladesmiths.

We'll see you in four days.

[INAUDIBLE].

Good luck to you, buddy.

[ROCK MUSIC]

BENTON: So it's day one.

I'm back home in Evansville, Indiana,

and I'm ready to get started on this Bhuj build.

I'm working on the dagger first.

I think it's the easiest thing to warm up and start with.

I really got to watch my dimensions.

This dagger, as I'm forging it, I'm

keeping in mind that where the ricasso and the transition

from the blade to the tang is, I got

to make sure I'm not too wide to go

inside the handle and the pipe.

I got to make sure I'm not too narrow

or this thing's going to rattle around.

So I really have a tight window that I need to fit in.

Good enough for now.

I made some great progress, but I've got a lot to do.

It's freaking me out.

JOE: It's day one.

I'm here at the home forge.

Get warm in here, man-- it's freezing.

I'm making a Bhuj.

It's a little bit boujie, I would say-- a little bourgeois.

It's not only a piece for warfare,

but it's a really artistic expression

of whoever's carrying it.

I'm thinking of doing some san mai,

so sandwiching it with a mild steel.

That'll just make it that much more tough.

I chose san mai to really bring the most out of these two

different types of steels.

The mild steel is very tough.

It can take a lot of bending without cracking,

while the hardened 51/60 in the center

is just coming down where I need it along the edge.

Just need to get the billet down to a more manageable size.

I hot cut off the excess.

And as I'm hot cutting, I'm putting a lot of stresses

on those welds.

And one of the pieces of mild steel's wanting to kind of rip

away.

That's pretty bad news.

From hot cutting it, all the stresses on it

found a weak point right there.

So in order to fix that delamination,

I got a few more tries at forge welding it up to the thickness

that I have.

If I get too thin, then it's a lost cause.

I just hope I can make this work.

Not only is it day two, but it is also my 28th birthday.

Creating a challenge weapon in my home shop,

that's a pretty cool birthday present.

Today, I'm going to start forging

the larger blade of the Bhuj.

So what I'm trying to do is split this tang off of here,

and I got to form my clip point.

Then I can draw my length out, and that shape will follow.

And then I can start getting that swoop

that I need for that Bhuj look.

Time to get this bad boy quenched.

This is the moment that I really need to nail,

and I am praying that this thing's going to stay straight.

I pull it out.

[LAUGHING]

Ah, that thing's harder than $9 worth of jawbreakers

and straight as an arrow, man--

pretty good birthday.

JOE: It's day two, and I'm looking at the blade.

And I'm not 100% on the laminations on the san mai.

So it's seeming to make the best sense just

to scrap it and start over.

I'm going to use a big old piece of leaf spring

and see what I can do a second time around.

Starting over with a 51/60 mono-steel blade,

time is really at a premium.

I may not finish.

So it's the start of day three.

I have to start putting a lot of puzzle pieces together

and do a lot of fabrication.

60's too hard.

So I think I need to temper this some more.

A little hard for my liking for what it's going to be doing,

so I'll soften it some more.

I'm trying to make sure that my blade gets up to temperature

and [INAUDIBLE] stress, so that way

I've got a nice flexible yet strong blade.

If I don't get these blades softened and more flexible,

they're more likely to snap.

Right now they're very brittle.

If I heat up the very end and keep heating up the end,

the heat will travel and draw the temper all the way down.

That's the best I can do right now.

I've got my dagger tempered, so I can put my handle on.

Then I'll slide my socket on, weld that beast up,

and we're ready to go.

It fits right in there.

My blade is completely assembled.

It's not pretty, but it would perform.

I think it's ready to roll, man.

JOE: So yesterday I forged out the blade of my Bhuj.

I forged out the stiletto, and I got around to heat-treating

the Bhuj blade.

Today I have to heat-treat the stiletto.

Heat-treating a stiletto is going

to be a little tricky because there's zero room for warpage.

So this thing needs to be dead straight to be

able to fit in that handle.

If it's not, I mean, it could hang up in there,

or might not even come out, or just rub against interior wall

and dull the blade.

So it's the moment of truth.

Yeah, it looks great.

It looks perfectly straight.

It's time to start chiseling in the elephant head

into the bolster now.

I'm choosing to put an elephant on my Bhuj

because that was the traditional creature

they would add onto it.

And I'd really like to honor the culture

and these amazing smiths for creating this.

There we go.

So the weapon as a whole I think is becoming a beautiful piece.

Joe, Benton, welcome back to the forge.

You fellas have had four days at your home forges

to work on your Bhuj with hidden stiletto blade.

Joe, how did it go?

It went well.

My blade's made out of leaf spring,

got a coil-spring stiletto, and some etch design work on there.

What about you, Benton?

I feel like my build went well.

My blade's out of 51/60, and my stiletto is 10/84.

It was a tough build, but I feel great about it.

Well, gentlemen, only one of you can be the "Forged in Fire"

champion.

And to determine which one of you it will be,

it's time to test them.

It will be a strength test, a sharpness test, and, up first,

the kill test.

Doug.

Bladesmiths, welcome to the kill test.

Your Bhujes look beautiful, but are they deadly?

Well, to find that out, I will take your weapon

and deliver killing blows onto pig carcasses.

Joe, you're up first. Ready?

I'm ready.

Let's do this.

JOE: My heart's racing.

My knees are rattling.

I just feel like anything can happen.

[ROCK MUSIC]

Nice.

Oh, man.

[SIGH]

First up, this blade is sharp.

The point is easy enough to get into the carcass

and smash on the way out.

It's got a great feel to it, nice stiletto.

There's even a handle that you put on this,

so it gets a nice look to it.

Overall, sir, this Bhuj will kill.

Thanks, Doug.

All right, Benton, are you ready to ham it up?

Ready to rock and roll.

Let's do this.