I'm Matt I'm Kerri
we are the stag my brother is a
Baltimore knife and sword we're going to
be building some of your favorite
weapons some weapons that you've never
seen before
this is man-at-arms reforged
Genji's dragonblade is by far the most
requested build by you the fans the
build complements all the craftsman
skills in the shop we're gonna be using
everything from traditional forging
techniques to modern fabrication to get
it done in September of 1937 the Montesa
Railway Company got the Commission from
the Japanese government to produce the
new source for the military the
innovation that produced those swords
was taking modern tool steel making a
pipe out of it and inserting malleable
iron in the center this produces a
perfect Forge weld where the soft core
is always symmetrical to the rest of the
blade the time the wa heralded as the
greatest innovation of the Japanese
sword considering the Genji is basically
modern-day Robocop we're going to choose
this method which is both traditional
and modern to produce his katana so
we're gonna do something a little
different on the lathe today typically
you see us put something round on here
and make something round what we're
gonna be doing today we've changed this
Chuck out to a four jaw Chuck allows us
to reach in and grab something that's
not round we're gonna drill this center
hole we're gonna step it up to a larger
size creating a center section so that
we can do what's called man Tetsu
construction we're gonna be forcing a
piece of mild steel up inside of here
prior to Forge welding that'll give us a
high-carbon outside this is w one tool
steel and on the inside we're gonna have
ten eighteen mild steel and that's going
to give us the flexibility in the blade
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why lily has been preheating the w1
section I've got the inside mild steel
pin sitting in dry ice this allows the
pieces to slide together with only
minimal effort from the press these
pieces actually had about ten
thousandths interference fit and there
was no way we could have put them
together without doing this
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after Kari made the high carbon steel
pipe and we inserted in low carbon steel
rod the shrinking of the outer jacket
locked the core into place and a handle
was welded on to the top and now it's
ready for Forge welding
you
the Ganges sword is the most
romanticized weapon his main weapon
actually are three large shuriken which
were going to cut out of some sheet
metal layer them together he treat him
and grind them to shape
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after cutting the body of our shortens
jobs now gonna plasma-cut all of his
overlays that are going to form the
three points
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to make sure he's a clean material and
where the welds have taken well billion
I'll uses a hot cut cuts most of the way
to create his tip form cools the piece
in water that allows the tip to just
break right off
this is the extra material I cut off
ahead matte polish and etch the
cross-section the white oval is where
our soft core is and the black is the
high carbon outside now you might be
wondering if I have a low carbon insert
will it affect the point will it affect
the edge no this is why the Smith Clips
over the tip this way and forges it over
I drew a chalk line approximating where
this soft insert will be and when I
forged the piece over I moved the soft
all the way to the back thus not
affecting the cutting capabilities of
the sword
using the face of a cross peen hammer
Ilya bevels this entire blade he'll do
it in a couple of different heats this
will allow him to control the curvature
a little bit more and he won't have to
deal with straightening as much
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Ginji is the master swordsman in
shuriken user and younger brother of the
schemata clan
Hanzo being the oldest and a master
bowmen Ginji disagreed with the clan
dealings and didn't want to have
anything to do with it this enraged his
older brother Hanzo and led to a very
violent confrontation
Hanzo thought he had killed him but he
was turned into a sideboard resulting in
a very robotic like sword after
heat-treating we're gonna notch in the
spine all the way down to account for
some overlays and some lighting fixtures
but to get things started I'm just gonna
do a pretty traditional grind and then
hand it off to Ilya for he treat
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while the surface of the blade is
cleaned up it's ready to receive the
clay here I warmed up my stolen on which
that makes the clay well the clay
actually does it protects some of the
blade from exposure to the quenching
medium in our case is going to be oil
when working with modern materials the
cleaning of the blade is entirely
unnecessary
except for maybe aesthetic purposes
however we still have to attach fiber
optics and electronics to the back of
the blade and it's way easier doing that
when you're working with a soft part of
the blade rather than hard so one can
argue that this procedure for this
specific build is completely necessary
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now to John's welded these up for Genji
shuriken so we're going to go ahead and
start grinding the edges on these either
real thick right now and we've got to
get these real Narrows to the nice and
sharp for throwing
being very careful not to bump the clay
off on the sides of the furnace Illya
watches to bring this sword up to a nice
long even heat brings it out and then
takes it into the oil quench
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as the blade comes out of the oil quench
and before it fully sets up Illya goes
over to the Vice checks it for
straightness and then sets it up for let
it cool
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after quenching and then tempering the
blade it's time to get it closer to its
final shape
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for these katana blades you don't really
want to add a secondary bevel when
you're done polishing it should be darn
near sharp
that has taken the blade through most of
the grits the sword has a pronounced
kissaki which means the kodaline the
differentiates the tip from the rest of
the blade is very prominent normally
this is set up a flat Whetstone's
however a platen grinder such as what we
have here is a decent replacement
possession
[Applause]
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up into this point the shaping of the
sword blade has been mostly traditional
but from here on out we're gonna do some
modern techniques to make this a blade
that a cyborg would use so first step I
have to do is I'm gonna trace our
overlay we're gonna sandwich the blade
on either side with two steel overlays
on our knees that's gonna be some
plexiglass and then some lighting along
the spine to give us that green dragon
blade glow that we all love in-game so
from here I'll pull out what I drew so
I'll go in and tweak those and make
those all perfect then I'll hand it off
to Carrie and I'll get to overlays cut
for our Hilton our handle assembly I'm
gonna cut one part flat and then we're
gonna hot form it around same here two
pieces hot formed over my power supplies
are gonna be hidden in here where this
round cylinder is so we'll just get all
our parts cut hot formed and get rolling
now that we have our designed for our
overlays finalized Carrie's gonna put
them into the plasma computer and cut
them out we need one for each side of
the blade so he's gonna mirror the
drawing and go right to it
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the material that we decided to make
these overlays from has been sitting
outside for a little while so it's got
some surface corrosion since that's the
case I'm going to use several Sanders
with progressive grits rough off the
material and then fully finish the
surface
after hand plasma cutting out his
patterns Illya is now gonna move out to
the forge gasps to turn that flat piece
into a nice round ovate piece that will
work as the guard for our sword
these overlays they're gonna lay on top
of this blade and they're gonna cover
the diffuser we're gonna make our
diffuser in lexan we have here we'll cut
that it'll be underneath and then we'll
be able to set full strip of LED panels
underneath and that's going to diffuse
the light and give us the glowing edge I
may have to do some sanding to get an
exact fit but I'm going to go to this
small band saw and cut out the plastic
to make it match as close as possible to
the steel overlay
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using the sheetmetal overlay as a guide
Carrie now matches the notches up on the
plexiglass it's going to cut them on a
bandsaw and intro a month later by hand
since he free handed his pattern
he realized after forming that it's a
little long it's gonna trim the fat then
weld it together and make that weld nice
and flush to the rest of the surface
so I've worked out how this overlay and
lighting system is going to work so I've
got this tape down but it's actually
double-sided so I've got LEDs on both
sides I'm gonna notch into the steel
it's gonna sit on the back of that spine
the diffuser will lay overtop we'll have
to cut the back of it to make sure that
it gets right where we want it to be in
the final once we have the blade satin
and polished it should really show this
and should diffuse the light over the
entire surface now that we have
everything fit just right to the blade
it's time to start welding it together
John's gonna use an aluminum spacer just
to make sure this thickness is stay true
weld the seams and then we'll blend them
all off on the Sanders
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she has videoing with that the pieces go
there's quite a few pieces that go
together to make this handle the first
is the one that's gonna hold our
cylinder and it's also like a trigger
guard Illya formed it and now he's
cleaning up on the scotch brite wheel to
give it a nice satin finish
after looking at this pummel you realize
that it's a lot like the production
pommels that we make on a day to day
basis I'm gonna go to the Sanders grind
a bevel and then knock all the corners
off should be about ready for assembly
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this handles a lot like a traditional
saya but has a futuristic looking shape
Billy's going to sand that shape then
return to the mill to carve all of his
detail in
if you look at the dragonblade you'll
notice that it has a green cylinder
underneath the guard I believe this is a
power source we're just gonna use some
tubing cut it to length and paint it
green later so we have the majority of
the pieces here ready to go this is our
diffusers we've sanded one side of them
so that they're smoking now so they'll
be a little bit brighter to hold that
light better and transfer it our cover
is going to get blackened and but
everything should fit up on the blade
nicely now this is the primary section
of the guard what will become our handle
with some overlays we've got some color
to lay in a little bit of shaping in
some detail and then to finish it out
you'll see that pommel that Matt made on
the end
overwatch has quickly become one of my
favorite games to play this build was
our first from the series and I'm very
proud to say that we've brought ginji's
dragonblade to life
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the game
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man-at-arms reforged we need to know
what you want the guys to build so tell
us in the comments below what weapons
you want to see next
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