I'm Matt I'm Kerry we are the Stagmer brothers 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 You guys have been asking for another challenge bill for a while
now and this time we decided to up the ante by using only tools and techniques from the
19th century we have chosen weapons from the fallout video game series we're gonna flip a
bottle cap to see you picks first okay for my fallout build I'm going to build
something simple the bladed aluminum baseball bat here i scrounged up an aluminum baseball
bat picked up some saw blades and found some old dirty barbed wire and field well
clean and polish all this up drill some holes and start assembling it John may have won the
coin toss but I really won the coin toss I get to make the oak bat with nails in it
batters up
here's a fun fact I actually had never seen someone turned something on a wood
lathe before when Sam first came to work for us he demonstrated for me and he turned a mini
baseball bat so now he gets to do it on camera and everything comes full circle
the first step in my fallout build is to go ahead and cut the grip off my back
then we'll take some sandpaper and sand the finish off
you
while Sam and John both work on their highly modified baseball bats I figured that would be
a waste of my skills since I'm a blade guy I'm gonna make a bladed weapon and I chose to do
cremes tooth which is a machete basically on crack it's arguably the most sought-after melee weapon
in Fallout 4 it's an upgraded machete in the game but instead of upgrading machete I'm going
to start from scratch I'm going to use some plate steel cut it out with a torch go to grind and get
it heat treated and finish it up machete is a close-quarters weapon that means it has a short
blade allows you to be able to fight and really tight areas so I'm gonna make my handle six inches
long and then I'm going to go up 22 inches and I'm gonna go ahead and make a mark at 28 that looks
like a pretty typical machete length that's the only thing typical about this weapon and so I'm
gonna just sketch this right on the plate you'll notice that the blade has really Wiggly edges
and rough edges and I'm drawing just nice smooth lines the reason being is I chose to cut this out
with a hand torch not a plasma torch but a hand towards it's gonna naturally make those raggedy
edges I'll just have to go in and sharpen them on a grinder and then we'll be good to go feeling
pretty good about this project I know it's early on that's Sam and John better bring their a-game
as you can see I'm struggling a little bit as I cut this I've actually never
cut any plate using a hand torch I've always had a plasma cutter ever since
I started as a sword maker but in the 1790s a German inventor named August von Marquette
invented a blow lamp so the torch has been around a long time this is an old-school
technique I just want to show you something different you haven't seen a man in arms yet
so I thought I chose a pretty simple build you know towards cut the plate grind it add some
handle slabs good to go but forgot I can't use my powered Sanders so I'm gonna have to file
this to shape I'm going to get right to it now or I just won't have enough time to finish this so
I'm gonna start with a round file I'm going to follow these natural serrations that our
torch cut added so I'll basically do that all the way around different size files different shapes
getting in on different areas flip it through the other side and then I got to go start cleaning up
this whole perimeter and doing the same thing save a little time on the perimeter I'm going
to use a hammer and just knock off some of the rough stuff left hand torch cut the next step
in our process is to go ahead and drill holes in my saw blades using the original cordless drill
now that we have two baseball bats and it up and the holes drilled in my saw blades the
next step is to go ahead and drill through the back alright I'm almost done adding all of our
outer bevels this has been a challenge not only because I have to do it by hand but as
you know usually I take something really rough refine it and make it look pretty in this case
I'm taking something rough and trying to make it even more rough I'm making sure I change my
angles as if maybe the torch cut edge is the edge itself so when I go to heat treat this
after heat treating I'm not going to do much cleaning up at all because I want it to look
all one-fluid rough piece alright now that my edges are done it's time to put the holes
in where my handle slabs are going to go I'm going to start by using a spring-loaded Center
punch that's gonna put a little divot it's gonna allow my drill bit to have a starting
place to bite into then I'm going to use this handheld auger and drill my holes
now that the holes are drilled in the bat using our hand drill I'm going to
go ahead and cut threads in since we're doing this old-style 19th century we're
going to use a hand tap and a good old wrench and do it the hard way
so I finished rough turning the bat and now I'm gonna move the sandpaper and just
smooth that whole surface out and progressive grits just like we would sand to bleed so I'm
going to start with a rough grit at a 24 and then move up to a 120 to twenty and then 400
now the batsman completely finished sanded to 400 grit I'm going to rub
this beeswax on use the heat of my hands to kind of get it in the wood
grain and then burnish it with the sawdust from the actual bat itself
now that I got the blade filed to shape and I'm happy with it it's time to heat treat I'm going
to be using the welding Forge it's going to give me a lot more heat and this is a short
blade so it won't affect anything I'm going to quench the blade into oil first for two reasons
one I want the blade to get nice and crusty just like it looks and fallout4 but this is
also called a sacrificial blade so I'm going to be using our holy oil quench tank because
well it has to have some poison damage this is the only way I know how to do it
after quenching it in the oil to get nice and scaled off a
few times I now get it up to my desired temperature and quench the blade in water
with Sam and John both making modified baseball bats I thought I was being slick by making a
bladed weapon but now Kerry's entered the game and he decided to a sword as well I hope mine
beats is the fallout challenge I'll be building the revolutionary Sabre it's a
relatively simple piece I'm gonna be starting from a railroad anchor which is a clip that
goes on the bottom of the track keeping it in place I've got a piece hot in the Forge
I'm just going to straighten it out and then we're going to size it and late from the bar
now that we have both saw blade secured to the bat John's going
to wrap some barbed wire around it this will not only add some extra support but
also gives it a little more badass look and it's exactly how it is in the game
I'm fitting with the nineteenth-century theme of the fallout bill I'm gonna straighten one of these
rails butts by hand and force the nails out of it for the baseball man named first has to turn
that railroad clip into a straight bar he does this on the amble he starts on the horn moves to
the flat gets it straight ready for the rolling mill Sam has decided to take the stock all the
way down to ask where he'll be running it through the rolling mill multiple times to bring it all
the way down to his desired size the rolling mill didn't even grunt rolling that rail cliff down in
a nice clean stock I'm gonna clip it to length and begin to force the nails using a hot cut
Hardy tool Sam Clips his pieces down the sides he'll then be able to draw them out from there
since I noticed John use some found objects and that's kind of the whole point behind the
Fallout game I decided to go ahead and use some wood from an old pallet it's gonna be
decent wood it's going to give us that old weathered look that's already been sitting
outside for a while next thing I have to do is lay my blade on top that piece of
wood use the holes I pre-drilled in the handle to be my guide for the wood part
since Sam has about a dozen nails to make it's going to show you a couple
different methods first he's going to draw a couple nails out by hand then
he's going to move on to the Bradley and show you how he does it there
now that I've gotten the length on this blade and shouldered in the tang I'm going to be doing
some hand beveling so that when I go to the filing and finishing I've got a lot less work
now that he has his nails nice and pointy Sam's going to move
to the vice clamp them in and upset the heads to harden my saber blade I'll be
coming from the atmospheric Forge and going directly into the clinching oil
to make sure the wood bat doesn't split while driving the nails through Sam's
going to drill some pilot holes he then heats the nails up and burns that round hole square
he's now ready to set those nails in permanently to create the form for this
guard I'll be using the edge of the anvil it'll delineate where I'm going to change
from a ball form to the section where the Tang has to come through I'll up set the ball form
driving it back on itself and I'll flatten out the area where I'll have to punch for the tank
so I pretty much finished the wood section on my handle got a nice little surprise after I
hand sanded and oiled it it's actually a very pretty wood but in the game it's
got some grip tape wrapped in a spiral and spiral back so now we got to cover
that pretty wood up so I'm just gonna take some charcoal grind some dust in my hand
just rub it all around get that nice and dirty all right with our handle now done this piece
is complete this might be the ugliest thing I've ever made but I sure I am proud of it I'm using a
small acetylene torch to heat up the Tang on this sword and burn it into the walnut handle you'll
notice the little notches on the Tang that's so that when I set it in epoxy it'll hold true
this challenge allowed us to use some new old techniques really happy with all these
builds I think we all killed it can't wait to see how all four of these do in the demos
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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.