[music playing]
James, Paul, congratulations.
You guys have made it to the third and final round
of this competition.
Now, when you came here, we threw a little twisted
Damascus challenge at you.
Now we're sending you back to your home forges
to recreate this iconic weapon from history.
Ready to see it?
Yeah.
Sure.
All right, that weapon is--
the darb sri gun chai.
I have never seen anything like this.
I can't even pronounce the name of this thing.
"Doob-tree goo-trabi?"
What did he say?
Good luck, gentlemen.
We'll see you in four days.
Good luck, man.
Good luck.
[music playing]
Day one, I'm ready to get hammering.
I'm going to be using 80CrV2.
It's a very good steel for impact and edge retention.
And I believe the tests that they're
going to be putting this blade through,
it's going to need a little bit of both.
This is a big chunk of steel, so it's
going to take a minute to get the tip forged down
to where I want it before I can start
drawing it out to the length.
[music playing]
The thing I'm struggling with the most
is the weight of this entire blade.
I'm having trouble keeping this thing straight
when I take it out of the forge.
It's the end of day one.
Pretty happy with the progress-- got it all drawn out.
I'm ready for a bath, and get started on this thing
first thing in the morning.
[music playing]
PAUL: It's day one here at my shop in Fairfield, Connecticut.
And I'm going to be making a darb sri gun chai.
For this challenge, I'm going to be making ladder pattern
Damascus, because it's really going to set
me apart from the competition.
This is 15N20, that's the 1084.
I got to make sure there's no grease or oil on them,
because that could affect the forge weld.
After I get the steel cleaned up,
I stack all the pieces up together
and do my initial weld.
I'm feeling really good that the welds have stock.
That's one of the most difficult parts of the entire process.
The next step is to grind in notches all along
the entire thing on both sides.
And what that's going to do is expose
the layers of the Damascus.
It's the end of day one, and I'm in pretty good shape
for the rest of the challenge.
[music playing]
Pretty nervous today--
we're going to do this heat treat this morning.
I'm only halfway through with the time.
So hopefully, if something does happen,
I've got time to make another one.
Look at that-- four leaf clover, right at my feet.
I hope it's a good sign.
[music playing]
I didn't feel any pings or pops.
I'm happy.
[music playing]
It's the last day, and it's about time
to start etching the blade.
This is the most magical moment of making Damascus,
because you get to finally see what the pattern's
going to look like.
I'm still getting streaks, though.
I don't get it.
It's just not at all what I wanted to see.
There's a bunch of decarb all over the entire blade, which
means I didn't grind deep enough,
and the etch is not going to come out right.
So I could either leave the decarb,
and the Damascus just won't be as good-looking,
or I could grind into the blade a little bit
and risk making the blade too thin.
[music playing]
I knew in order to save the pattern,
I really had to just go back to the grinder.
And I think it's pretty good.
This is the Damascus I wanted to see.
I'm still kind of concerned that the blade is
a little on the thinner side.
But there's nothing I can do now.
[music playing]
JAMES: Here comes the light at the end of the tunnel.
So far, I've got the blade done.
So I'm going to start working on the handle.
I don't have long enough drill bits to drill
all the way into that handle.
So I'm going to have to carve out a channel for that
tang to sit in, and make sure the wood
marries back together nicely.
Yeah, baby.
Made it a little of my own by adding some fur
from the land around my house.
I think that's going to add a little special touch.
It is a little on the heavy side,
but it's balanced perfectly.
It's very wieldable.
I'd say, yeah.
All I can tell you is grab it by the rabbit.
All right, bladesmiths, welcome to the kill test.
Your darb sri gun chais look intimidating.
But are they deadly?
To find that out, I will take your weapon,
deliver some killing blows to this ballistics dummy.
James, you're up first.
You ready for this?
There's nothing I can do to stop it.
All right, let's do it.
[music playing]
To say I'm nervous right now is an understatement.
At this point, it's out of my hands.
I just hope it can hold up.
[music playing]
All right, James--
first up, that's a beast.
It's very forward heavy, so it definitely feels like a chopper
all the way through.
Now, your handle here-- by adding this fur around it,
I can't get a good grip on it because it's so soft.
Now, your edge is sharp.
Overall, sir, it'll kill.
Thank you.
All right, Paul, your turn.
So are you ready?
I'm ready.
DOUG MARCAIDA: Let's do this.
PAUL: I built my blade to be very light.
It definitely makes me nervous seeing the ballistics dummy,
because I know there's a lot of hard bones in there.
And I'm definitely a little bit worried that it could bend,
even break in half.
You never know what's going to happen.
[music playing]
All right, Paul--
first up, I really appreciate the Damascus pattern
that you brought out here.
Now, the fact that I can hold the weapon out
extended like this shows just how light this weapon
is for its size.
And because of that, I can cut deeply into this
without using the weight, just velocity alone.
But after that strike through the skull,
it's picked up a little bit of a bend.
Overall, sir, it will kill.
Thank you.
[music playing]
All right, gentlemen, to test the strength
and overall construction of your blades,
I'll be chopping into these pots.
Now, remember, this is not about what
your blades do to the targets, but what the targets
can do to your blades.
James, you're up first.
Are you ready?
Let it happen.
DAVID BAKER: OK.
[music playing]
Phew.
[music playing]
This is a shoulder-ripping monster.
Once you start this thing moving, stopping it
is really rough on the shoulders.
The fur around the middle here--
it's a neat look, but it's very slick, actually.
And then your edge is still sharp.
You nailed it.
Good job.
Thank you.
DAVID BAKER: All right, Paul, you're up.
Are you ready? - Yeah.
DAVID BAKER: OK.
[music playing]
PAUL: I see the pots, and I'm very worried.
I feel like it could bend my blade
even more than it already is.
If something goes wrong, then I'm finished.
[music playing]
(WHISPERING) Good job, dude.
(WHISPERING) Thanks.
DAVID BAKER: All right, Paul-- right off, this weapon
has a feel that is excellent.
I can literally use it with one hand.
The edge-- still sharp.
Nicely done.
Thank you.
[music playing]
All right, bladesmiths, to see how sharp your weapons are,
I will try to cut through these pineapples.
James, you're up first.
You ready for this? - Let's go.
DOUG MARCAIDA: Let's do this.
[music playing]
(WHISPERING) Nice.
Nice job.
(WHISPERING) Thanks.
All right, James--
just a little off the top.
Your edge is sharp, cuts cleanly all the way
through these pineapples.
It will cut.
Thank you.
All right, Paul, your turn.
Ready?
Yep.
[music playing]
There you go, man.
Gosh.
[music playing]
All right, Paul, it is razor sharp.
Just the thinness of your metal here
cuts through, no resistance.
If you look at the pineapple heads,
they're all still standing right there.
It's very sharp.
And more importantly, it will cut.
Thank you.
[music playing]
James, Paul, you've both done an incredible amount of work.
However, there can only be one "Forged in Fire"
champion in this competition.
And that champion is--
Paul.
Congratulations, you're the new "Forged in Fire" champion.
James, please surrender your gun chai.
JAMES: Well, I'm pretty happy I've made it this far.
I don't think I could be too disappointed in what I've done,
considering how the weapon performed.
My blade was just a little too heavy.
Congratulations. - Great.
You deserve it, buddy.
Good job.
JAMES: It's been a really great experience.
I did the best I could.
No matter what you do in life, there's going to be challenges.
And you're not going to always succeed.
Just get back up, get back on the horse.
[music playing]
WIL WILLIS: Paul, congratulations, you're
the "Forged in Fire" champion.
And that is a title that comes with a check for $10,000.
Good job, brother.
Thank you, thank you.
I just couldn't be happier.
This is, like-- got to be the craziest thing that's
ever happened to me so far.
I mean, I know I'm only 19, but I still can't believe it.
I'm the "Forged in Fire" champion,
and it feels incredible.
[music playing]