I'm Matt I'm Kerry we are the stagmer brother's of
Baltimore Knife and Sword. we're going to be building some of your
favorite weapons some weapons you've never seen before this is man-at-arms Reforged
in Dark Souls lore sir Knight Artorias was one of the four Knights of Gwyn who battled the
darkwraiths his great sword was born from the soul of the great gray wolf SIF and according
to lore it strikes harder against dark servants the man-at-arms team is super excited to build
this weapon because the sword is incredible humongous ornate intricate with tons of detail
and beautiful we're building the weapon now because the newest iteration of the game Dark
Souls 3 drops Tuesday April 12th at this point I'm sure you guys are starting to realize why we turn
this build down in previous seasons just your size of it and the ton of detail that goes into
this piece it's going to make it a really long project it's going to be a brutal forging and a
whole lot of grinding Ilias going to start this off by moving the nasal power hammer and start
breaking down this huge bar turn into a flat bar and then he's going to start adding in some detail
now that we have a large portion of this metal broken down to a bar Ilya
has a much better sense of the amount of metal he's going to need so it cuts
off the excess goes back to the Forge and starts forging on the end again
at this stage you can see Ilias got the blade drawn out a lot further but there's still a
long way to go he's going to work on the flat hand on the sides and continue to draw that
out till we have a lot more of that blade shape we're looking for in a defined tip
so from the multiple images that we found for the great sort of artorias we actually have
discovered that in some of the pictures we find the pieces around in some pictures we find that
they're hexagonal what we've decided based on how we're doing the engravings is that the very top
fitting will actually be a round section on the pommel the lower part of the pommel which we're
going to be engraving is hexagonal those will actually become tapered off on an angle before
we do the engraving and then this is the lower part of the handle that sits on top of the guard
I've actually taken a very large piece of 4140 and cut it hexagonal I'll cut this last piece and get
it all even and then this also gets engraved all the way around we'll be doing that on the
CNC mill there's three separate patterns that have to be engraved into this hexagonal part
then they're duplicated on the opposite side I'll be using the CNC milling machine to cut these in
the last forging we have to do on the power hammer is to pull out
those ears near the shoulder it's just going to work real carefully
on the side using the side of the dies to make those more defined
now if that's done he moves to the anvil and begins doing some hand beveling right
around that area just to create a little more width and save me a little time in the grind
so this will be the great sort of artorias in one of our previous episodes matt said if we
can forge it he can grind it well I made his job a little bit easier by starting a little
bit of a bevel right here the next thing is for him to grind it to shape all right
we got our blade back from forging looks pretty good I only have to do a little
bit of profile grinding on this I'm gonna do is I'm going to start here at the ears
get those Trude up then I'm gonna move to the point I'm a little guy so grinding these big
blades is a huge challenge this sword it's definitely gonna put my skills to the test
the grinding the edges on this blade I'm gonna start by hogging off a lot
of material horizontally I'm not gonna leave it as a hollow grind like I'm gonna start off
that way John's gonna help me by holding the end of the blade as I hollow grind it
and then I'll move on to going up and down and turn that into a flat grind man now begins the
arduous task of vertical grinding this sword this will give us our final form for the edges
I set up my little embossing tool here it only sets up my lines then I have to go in and refine
the lines of the series of armoring hammers great sort of artorias is certainly a beautiful
piece of design it's an intricate piece with a lot of subtle variations and details the sword
is grotesque and beautiful at the same time the affection with a grotesque of fascination
with it dates back to the ancient Greeks with a mythology of chimeras and monsters gods coming
out of each other's heads and slaughtering each other that fascination brings about the rest of
the Western tradition all the way up to the 19th century and we produce myths of the modern age
like Dracula Frankenstein we get a fascinated with a sublime moment when the human existence
is so minuscule in front of the terrible in facing our mortality and here about comes the videogame
tradition of designing horrible situations situations where only demigod can win the
day the great sort of Victorious is one of the few pieces of game design that really embodies
that tradition from the ancient Greeks through the 19th century enter the modern digital age
going back and forth between a heat source and some oil Ilya
blackens down the center sections for the sword
he now goes to the scotch-brite to create highlights on these pieces
so I prepared the section for the lower part of the handle where it meets the guard I've
got to cut a few more beauty rings into it you can see I've got some pieces mark here
it also has to be board so that we can put a large section of a Tang through it I now
have the pommel section already set up so that the ornamented disks fit on it now I've got to
take it and make the spike or bullet form I'm going to use the automatic feed on the lathe
to make that smooth and much finer using the CNC plasma John cuts the wing sections of the
guard these will be pre forms that Illya will Forge and sculpt to shape using the fly press
more like a clamp Ilya takes the pipe that will become the guard ends brings up the temperature
and then bends it to match a previous piece that he checked for curvature the pieces of this guard
aren't round they're actually somewhat oval so Ilya begins to drive it down to match that form
philia now takes a hand grinder and cuts the form into the tubes that he curved earlier in the forge
Ilia takes these quarter-inch steel semicircles and rolls them into a cone this will attach the
guard ends to the center section he's not exactly sure how long they're going to be
so after he rolls them we'll cut them to shape now that we have the form of these flared guard
sockets Matt cuts the overlaps so that we can weld them together now that these sockets have
been welded together Illya is going to squish them down so that they make that transition right from
the round section of the guards into the main center section as it's mounted to the blade
so I finished carving the guard parts and right now what's left used to weld them together the
top is going to go into this socket right here and John will weld it on the inside after that
Matt is going to scotch-brite it and prepare the pieces of wood that go inside completing
the guard I'm gonna start by using big piece of rectangular wood all right now it fits pretty good
see though right here I got to change my angle just slightly so
it sits flush and my two pieces meet underneath our collar here
alright now we got our wood fitted it's just roughed in though still
gotta go in on the narrow wheel and add a little bit of detail on the
centerpiece here cut them off and then we'll get everything welded together
central ridge of the blade has two overlays on either side one towards the center and one down
towards the tip Illya is going to use the Dremel just like you did on the Gard parts and carve
that detail in I've set up some of my long lines with a narrow wheel on the grinder that saves me
quite a bit more time with the dremel tool now I'm going to go back in and start with a carbide
cutter turning this into this using a sander Illya Nell blends the welts off on these winged overlays
okay I'm now in the final stages of polishing out the edge bevel in order to get a nice crisp
clean straight line which is impossible by hand with an angle grinder I've clamped a sacrificial
straightedge to the blade and then I'm going to grind right up to it with an angle grinder
alright let's take the clamps off and see how it turned out we have a nice clean crisp
edge the next step is to deck the top and then polish it out with scotch brite disks
alright the last few steps that I'm in charge of on this bill before we can start assembly
is getting our horn parts all blackened I've gone ahead and painted the wood parts black
now I got to get the outside steel shells completely darkened then I'll insert the
wood epoxy them together and we can start welding it all up this one's already been
blackened I'll go ahead and heat this up in the Forge dip in oil and heat blue this one as well
we went ahead and masked off the edge of the blade the whole edge needs to stay nice and bright the
center is gonna get really dark so we're gonna use some black oxidizer scotch brite pad to apply it
just keep scrubbing that Center until we get our desired darkness then we'll clean it take
the tape off the edge and everything should be good to go first it turns kind of copper color
then it turns green then it gets into the black I'm gonna scrub the overlays as well
we'll then highlight the surface leaving the background nice and dark Matt pulls back the
masking tape to reveal the crisp edge where the black and silver meet so the handle for
Dark Souls in this case is not very long and doesn't have a lot of leather there's a lot of
other metal parts that are fitted to this we've already black in the background on this piece and
then re polished the foreground using a scotch brite wheel now we're gonna adhere the leather
it's gonna go in here wrap over itself we're gonna glue it in place it's gonna have some epoxy at the
very end make sure everything stays permanently and then we'll lock it down with that big palm
now we have our overlays welded to our main plate it's time to get our
horns fitted you can see I went ahead and notched a waste of material here
so everything fits just right now I got to go and repeat it on this side
all our hard work has finally come down to this it's time to start construction
now that everything's fit properly John can now begin welding the horns onto the base of the guard
we can finally get our first glimpse of this massive sword just got to do a few
touch-ups here and there that'll be ready for the demos the great sword of artorias really
pushed us yet again it allowed us to make some decisions on how we would do certain things in
these builds that I'm sure is going to allow us to do more elaborate pieces in the future
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for watching 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