Saw-Toothed Dusagge Turns Every Strike Into a Kill Shot | Forged in Fire

Bladesmiths compete to forge serrated dusagges with complex specs, tested for sharpness and durability in Forged in Fire.

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Key Takeaways

Complex blade designs require careful layering and forging techniques to avoid structural flaws.
Serrated edges must be balanced to maintain sharpness without compromising blade strength.
Dynamic testing simulates real-world cutting and stabbing scenarios to assess blade effectiveness.
Multitasking during forging is essential to meet tight deadlines in blade competitions.
Winning blades combine aesthetic Damascus patterns with functional design and durability.

What the video covers

Bladesmiths are challenged to create a serrated dusagge with specific blade length, curvature, and serration requirements.
The blade must have a serrated sharpened forward edge and at least eight inches of sharpened serrations on the spine.
Competitors use Damascus steel and wrought iron billets to craft complex layered blades with unique patterns.
The forging process involves multitasking to complete the blade, pommel, and guard within four days.
Blades undergo a dynamic KEAL test involving chopping and stabbing through pig carcasses and animal hides.
The blades are also tested for strength and durability through rope and barrel chopping challenges.
Judges evaluate the sharpness, cutting ability, blade integrity, and overall execution of each weapon.
Some blades show cracks or imperfections that are repaired during forging to ensure performance.
The competition is intense, with contestants aiming to win $10,000 for the best performing dusagge.
Jason wins the competition with a well-executed blade that performs excellently in all tests.

Chapters

What are the key blade specifications for the serrated dusagge challenge?

The blade must be between 23 and 25 inches long, curved, with a serrated sharpened forward edge and at least eight inches of sharpened serrations on the spine. The hilt must include a complex clamshell guard.

What materials do the bladesmiths use to create their blades?

Competitors primarily use Damascus steel made from 1095 and 15N20 steel layers, combined with wrought iron billets to create complex layered blades with unique patterns.

How are the blades tested during the competition?

Blades undergo a dynamic KEAL test involving chopping and stabbing through pig carcasses and animal hides, followed by a strength test involving chopping ropes and barrels to assess durability and sharpness.

Full Transcript — Download SRT & Markdown

Speaker A

Bladesmiths, over the next four days we want you to build this. ♪ ♪ A serrated dusagge.

Speaker A

- What the [bleep]? - Yours will have to fall within these parameters: Your blade will have to be between 23 and 25 inches and curved.

Speaker A

It will also have to have a serrated sharpened forward edge and at least eight inches of sharpened serrations on the spine.

Speaker A

Now, the hilt must be complex and feature a clamshell guard. Good luck. We'll see you guys in four days.

Speaker A

- Good luck, man. ♪ ♪ Plan is, get my Damascus billet made. 1095 and 15N20 is what I'm using.

Speaker A

My plan is to make a wrought-iron GoMai Damascus billet. My initial billet is only 15 layers.

Speaker A

I'm gonna draw it out enough, cut me a chunk off, put me a single piece of 1095 for my core, add my two 15 layers to the outside giving me 30, and then adding two wrought-iron billets to the outside of that.

Speaker A

Wrought-iron billet in the fire. I hope this will show off my skills, especially for the judges.

Speaker A

As I'm grinding these in, they're coming out gorgeous. Dude, that thing looks gnarly. It's time to quench.

Speaker A

♪ ♪ Oh man. [bleep]. I found a crack. I'm gonna clean it out as best I can and kind of see how deep it goes.

Speaker A

If this runs any deeper, I've got to start over. ♪ ♪ This crack, it's not that deep, not detrimental.

Speaker A

So I run this nice weld right down the spine. And boom, problem solved. ♪ ♪ - We're back at my home forge, and I plan on making a Damascus blade.

Speaker A

And the Damascus pattern I'm going for would just be, like, a random pattern just because it's a complex build.

Speaker A

All right. To get this blade done on time, I'm gonna have to forge the pommel and the guard at the same time as the Damascus.

Speaker A

It's just all about multitasking and working at the same time. All right. Everything's looking pretty good.

Speaker A

Hopefully, I can turn something in that makes me an extra $10,000. The one thing that I have to worry about is overgrinding the serrations and getting them too thin.

Speaker A

Because it could make the blade roll during testing, and I could be eliminated. Turned out perfect.

Speaker A

It's time to quench. ♪ ♪ That was nerve-racking. Sweet. I'm super happy about how this turned out.

Speaker A

That's a relief. [chuckles] ♪ ♪ - It's morning of day one. I'm back in my home forge hoping to get the billet stacked up and drawn out a couple times.

Speaker A

I've never made anything like this before. I've been saving it for this time, I guess, you know.

Speaker A

So I think it's gonna be a challenge, but I think it will be a lot of fun.

Speaker A

I'm gonna get the billet restacked and start making crushed Ws. You can't rush this part at all.

Speaker A

Matthew kind of inspired me in the first round, so this is gonna be pretty ambitious.

Speaker A

The hardest part will be, you have to turn it from flat layers to vertical layers, and they automatically want to shear apart if the welds aren't set properly.

Speaker A

It's kind of like how the Oreos want to come off the cream, to be honest with you.

Speaker A

The weld is set. Everything looks good. Nothing's split apart. So I'm happy with that.

Speaker A

Gotta make it right. Otherwise, there's no point in doing it, right? I think I have it where I'm happy with it.

Speaker A

♪ ♪ - Well, gentlemen, welcome back to The Forge. Here we are after four days with you guys back at your home forges building the serrated dusagges, and they look beautiful.

Speaker A

Well, we've got some serious tests coming up for you, but first up, the dynamic KEAL test with Doug.

Speaker A

♪ ♪ - Bladesmiths, welcome to our dynamic KEAL test. ♪ ♪ Matthew, you're up first. You ready?

Speaker A

- Absolutely. - All right, let's do this. - I'm so pumped. - [laughs] ♪ ♪ [heavy rock music] ♪ ♪ - Nice job, man. - Thanks.

Speaker A

♪ ♪ - All right, Matthew, this is a heavy blade. It chopped deeply into the pig carcass.

Speaker A

Stabbing into this animal hide, it was a nice clean slice. But because of the weight on this, it kind of affects my recovery.

Speaker A

But overall, it will KEAL. - Thank you, sir. - All right, Bob, you're up next.

Speaker A

You ready? - Absolutely. - Let's do this. ♪ ♪ - I've never built anything like this before, so I'm not sure how this is gonna turn out.

Speaker A

♪ ♪ [heavy rock music] ♪ ♪ - Nice job. ♪ ♪ - All right, Bob, there are sections right up here that are sharp, but the rest of it are not sharp at all.

Speaker A

And it ripped rather than cut it cleanly. But if you look at the pig carcass, your weapon will KEAL.

Speaker A

- Thanks, Doug. - All right, Jason, your turn. You ready? - Yep. - All right, let's do this.

Speaker A

♪ ♪ - I've missed out on $3,000 so far, and I really want to take home the 10,000.

Speaker A

My worst fear would be the handle or my blade could fall apart. I am really, really nervous.

Speaker A

♪ ♪ ♪ ♪ - Nice. [heavy rock music] ♪ ♪ - Yes. - [laughs] - Good job, buddy.

Speaker A

♪ ♪ - All right, Jason, your edge cuts nicely when it's going across the pig carcass.

Speaker A

In the animal hide test it sliced nicely. The forward weight does allow for nice cuts.

Speaker A

So the usage of your dusagge, it will KEAL. - Thanks. Thanks. ♪ ♪ - All right, gentlemen, welcome to our dynamic strength test, the rope and barrel chop.

Speaker A

♪ ♪ - Matthew, you're up first. You ready? - Let's do it. - Okay.

Speaker A

♪ ♪ [heavy rock music] ♪ ♪ - [gasps] ♪ ♪ Oh [bleep]. ♪ ♪ - All right, Matthew, it's a heavy weapon but did a good job cutting the ropes, which is good, 'cause a lot of these large serrations kind of hang up on stuff

Speaker A

as opposed to cutting. Edge is still as sharp as when it started, so nicely done.

Speaker A

- Thank you. - All right, Bob, are you ready to go? - Ready as I'll ever be.

Speaker A

♪ ♪ [heavy rock music] ♪ ♪ - Ohh. - Nice job, man. - [scoffs] - All right, Bob, right off, when I get down to your handle, it's a little wide at the top, but this taper, on that first cut, I nearly sent it flying.

Speaker A

It literally hit that rope and came down. I was on the pommel. But other than that, there's no damage to the blade, so well done.

Speaker A

- Thank you. - Jason, you ready? - Yep. - All right, this will be fun.

Speaker A

♪ ♪ [heavy rock music] ♪ ♪ - Nice. ♪ ♪ Whew. - Good job, Jason. - Thanks.

Speaker A

♪ ♪ - All right, Jason, your blade held up beautifully. It's definitely sharp, cut beautifully.

Speaker A

The steel looks good. The execution looks nice. And it definitely performed well, so good job.

Speaker A

- Thanks. The bladesmith winning this competition today is... ♪ ♪ Jason. Very, very well done.

Speaker A

With 10,000 I'm gonna buy a Harley and take my kids on vacation. ♪ ♪

Topics:Forged in Fireserrated dusaggebladesmithingDamascus steelblade forgingknife competitionblade testingKEAL testrope choppingblade durability

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