Speaker A
Bladesmiths, over the next four days we want you to build this. ♪ ♪ A serrated dusagge.
Bladesmiths compete to forge serrated dusagges with complex specs, tested for sharpness and durability in Forged in Fire.
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.
Summary
- 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
- 00:00Challenge Introduction and Blade Specifications
- 00:30Billet Preparation and Damascus Pattern Planning
- 01:30Forging Process and Multitasking
- 02:40Billet Stacking and Complex Layering Techniques
- 03:45Dynamic KEAL Test Begins
- 06:00Individual Blade Testing and Feedback
- 07:50Dynamic Strength Test: Rope and Barrel Chop
- 09:15Final Judging and Winner Announcement
Full Transcript — Download SRT & Markdown
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
