I'm Matt I'm Kerri we are the stag my brother's a Baltimore knife and sword
we're gonna be building some of your favorite weapons and some weapons you've never seen before
this is man-at-arms reforged we were very excited when Smith and Forge hard cider
challenged us to make nozzle from Lord of the Rings then they told us we could only
use old-school techniques so we're using charcoal today it's going to be different than the forced
air propane that you normally see issues in this case we're using probably about 20 pounds
per hour in charcoal I'm using w1 tool steel from Aldo Brunel as Kerry places the hot steel
into the anvil Sam not only sets the pace but also the placement for the striking for le ni
Sam removes the blade from the hot charcoal and goes to the anvil and refines the tip
now let the blade shape is fully refined Sam begins the beveling he starts at the
point and draws the bevels back towards the shoulder Sam tends to make this look really
easy even some of the most seasoned sness struggle through this process
stop hammer time my friends at Smith and Forge challenged us to do this build using only 19th
century tools and techniques they were generous enough to share this 19th century power hammer
with us this design was patented by Christopher Bradley in 1891 way this hammer works is it
has a spinning clutch as soon as you engage the foot pedal engages everything else and
it bounces on those leather springs to remove excess material we hot cut the Tang to length
Sam leads as Ilyas strikes to bring the Tang to its final length after nailing the blade
to a two-by-four I use an age-old draw filing technique to start defining the bevels on the
blades you have no power tools still don't have an excuse to create the puller down the center
of the blade I'm gonna be using a hand scraper you can see as we use the scraper it generates
so much friction that the little chips come off actually you're smoking so after using
the scraper the Ilya made too rough in the puller now moved on to using a file keeping
the heat on the blade even it's not always the easiest thing to do in a charcoal Forge once
the sword is reach temperature alia pulls it from the charcoal Forge and clenches it
in heat treating oil I'm getting ready to cut the stock for the guard for narshall normally I would
use the bandsaw but since we are stuck using 19th century tools I'll be using the hacksaw
using a spring sway John the power hammer Sam captures the metal on either side of
the central portion of the cross card this is an essential process
to leave enough metal to become our pointy coin block on the hill
now that we've done most of the rough work on the power hammer we're gonna move to the hand
hammer after drawing out the tines Stan uses the Horn of the anvil to finish the finials on
our guard can't exactly use my beloved grinders so what I'm gonna do is I'm gonna clean up the
guard using a trusty nicholson file probably be at this for several hours done about maybe 10%
of the guard for about an hour in a long way to go but we'll get there to create the triangular
holes in the ends of the finials for the guard Sam made a special tool that will allow him to
punch that shape that we're looking for using a radiused file that defines the facets on the
Quilliam block of the guard once I get my shape we're fine I'll going with sanding sticks and
make it pretty awesome out using the spring swage on the screw press Sam and I capture the metal to
draw out the neck of the pommel Sam places the pommel blank onto the Horn of the anvil
by Ilyas strikes for finding that much-needed arc at the end of the palm using a trying your
punch Sam puts a hole through the palm as a file to clean up the perimeter of the problem I keep
doing this not only to clean the surface but I also gotta wait until the radius in here matches
this radius now I got to start the sculpting Peter lion the actual guy who makes these swords
for the Hobbit in The Lord of the Rings movies I uses a lot of different sized contact reels and
a lot of different grinders so doing this by hand it's gonna be quite a task after heating
the base of the neck of the pommel sam up sets it giving us a nice transition into the handle
the punching on this pommel is both off-center slightly and not quite the final form that we
need I'm gonna do all of this with hand files to get it to the proper shape once I've got
exactly the form that I want I'm gonna take this and I'm gonna hand it off to
Illya for the engraving using chisels that he made himself Illya engraves the pommel
we got our basic parts all forged and cleaned up I'll go ahead and
do a rough assembly of the parts Tang will get shortened fasten our pommel
can't wait to go to the demos and hunt ourself some more okay
so maybe we were leading you guys on just a little bit with that but we've been looking
for the right opportunity to show you what would happen if you don't temper your blades after a
treat and this is if we broke the shards of the sword into even smaller pieces in the
movie the sword is reforged like this the shard is attached that is no way to reforge a broken
sword you don't get a solid construction like that the best way to reforge it is
the traditional Japanese tile stacking technique because their way all the tiles come in contact
with each other fully and the sword is drawn out this is how the sword will be whole again
after bringing all the broken pieces of the sword
up the temperature we take it over the anvil and reweld it
we're going to be folding the shards several times and doing more welding
we'll need to do this to make it one solid clean piece again
now that we've reforged this blade to form Sam for a second time begins beveling the blades
by hand this blade being so much longer than our Forge Ilya carefully moved the blade in and out to
get even heat using the heat from the charcoal fire Billy a tempers this sword he's watching
for the color change down the blade straw is the color work typically looking for it's okay if you
see the center go up into a light plum but we're trying to stay away from any blues now that we got
the blade reheat treated and tempered this time it's time for me to begin filing all over again
using a handsaw Sam cuts down woods that we can begin to carve this handle
using a chisel Sam cuts away the area where the Tang has to go
keeping up with the challenge I'm going to use the method called catching edging works
by applying resist to clean polish metal and then submerging in an acid with a purpose of
eating away down protected surface now with the resistant place mat moves the blade to the etchant
now that we have the guard and pommel attach to the blade we
lay on the sandwich pieces of wood for the wood handle and cover in leather
very bright was that sword when it was made whole again the light of the Sun
shone redly in it and the light of the moon shone cold and its edge was hard
and keen and Aragorn gave it a new name and called it anduril flame of the West
you
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