Nick, Josh, congratulations.
You guys are in the third and final round
of this competition.
Now, when you came here, you faced
really tough challenges that escalated
throughout the first two rounds.
Now we're sending you back to your home forges
to recreate this iconic weapon from history--
the zhanmadao.
JOSH: Holy [bleep].
This thing is huge.
[music playing]
Today, I got to try and figure out forging on this blade.
I've never made anything as big as this before.
So it'll be a unique challenge.
This is what I'm starting with, a big old piece 5160.
My forge only has about 18 inches.
And obviously, working on it a little bit at a time.
Try and keep it simple, make it something drawn out to size.
This thing is going to be gigantic.
[bleep] damn.
We've got the length.
It's a good start.
End of day one, I got the whole plate forged
out to a real rough shape.
Plan for tomorrow is to get to the quench
by the end of the day.
NICK: Yesterday, I was able to get the blade
shaped to where I want it.
Now I can get busy grinding, and hopefully,
by the end of the day, to get it quenched.
This is going to be a day filled with attention to detail.
This is the most nerve wracking part.
This is kind of the make or break moment.
So get it in the oil, perfect.
I pull it out, [bleep].
I didn't get a curve on it.
I need it to have a curve on it, because that
will allow it to function the way it needs to.
I've got to stick it back in the fire
and I've got to get it quenched.
This is not what I wanted to have happen.
So here we go again, quench number two.
It didn't break.
Best off, there's a little bit of a curve in it.
Day two was an adventure.
Pretty happy with where I'm sitting right now.
So what I'm hoping to have done tomorrow
is get the guard fitted up and be ready for the final day
of fit and finish.
JOSH: Morning of day two, goal for today
is to get everything heat treated.
I'm going about everything I can to try and get as even
as possible, but there we go.
Coming out of the quench is going to be a real challenge.
So I clamp it down with some two-by-fours.
The idea here is to help try and keep it as straight as I can
while it cools.
End of day two, I have a quenched blade.
So far, so good.
NICK: I'm doing OK.
A little tired.
Coffee and hate, that's what I'm fueled by.
Just kidding.
Just coffee this morning.
The sword looks phenomenal.
Now I can really start focusing on the fit and finish.
So I'm going to start working on my guard.
After a lot of fire work, I get the guard
bit right up to the shoulders.
It looks perfect.
Now it's time to start securing everything.
That seam there I'll fill with a piece of cord,
and then that's going to be wrapped back to 12 inches.
I've got to finish the handle, but I'm comfortable that I can
get this blade done tomorrow.
JOSH: Goals for today are getting
the blade cleaned up and ground and then
move to working on the handle.
Got the bevel ground in.
Now I'm going to start working on getting this handle fit up.
I'm going to glue these two pieces
together, do some sculpting.
I'm actually going to make it a little bit
smaller than I would, because I plan on doing a wrap.
Have a little bit of time left.
So start working on the shape of the guard.
Doing a little fit on the guard.
I'm happy with the shape, overall.
Tomorrow is going to be final assembly, glue up,
all that fun stuff.
I'm just glad Will hasn't shown up so far.
I'm glad there's no more parameters.
I got plenty of them.
Yeah, that'll work.
Bladesmiths, welcome to kill test.
Well, your zhanmadaos aren't pocketknives.
They definitely look very long, but what kind of lethal damage
can they do?
To find that out, I will take your weapons,
deliver some slashes and killing blows on this boar carcass.
Nick, you're up first.
Are you ready for this?
Yes, sir.
[music playing]
All right, Nick, let's talk about your weapon here.
Now, the design you have, I was expecting a little bit more
of curve.
Because of how straight your blade,
it feels more like I'm chopping before I'm drawing.
But as you can see, it will kill.
Thank you.
All right, Josh, your turn.
So are you ready?
Let's do it.
[music playing]
All right, Josh.
Let's talk about your blade here.
The balance is good.
And as much as I can feel the power in there,
I can wield this weapon and develop some speed and power.
And the curvature that you have here
does exactly what this kind of design is meant to do.
Every cut was very deep on this carcass,
enough to where it cut all the way through.
And more importantly, it'll kill.
Thank you.
All right, gentlemen.
Welcome to the strength test.
And to test the strength and overall construction
of your blades, I'll be chopping into pots and this horse skull.
And remember, gentlemen, this is not about what
your blades do to the targets.
This is about what those targets are going to do to your blades.
Nick, you're up. Are you ready?
Yes, sir.
[music playing]
All right, Nick.
So there's not really any chipping
or rolling that I can feel.
It's just sort of--
it's lost its fine edge.
Yes, sir.
Most of these weapons have a bit more of a curve, and this--
it's got about a slight curve as I could call a curve.
Yes, sir.
It's a very, very flexible blade, but it did well.
So nicely done.
Thank you, sir.
All right, Josh.
Let's do it.
[music playing]
So, Josh, very well crafted blade, which I like.
The guard, the dimensions, the size
and the shape of the handle, all really beautiful.
Unfortunately though, we've got some rolling
on the edge of this blade.
You hear that?
Yes.
You put an incredibly fine edge on this.
And it showed in the kill test, but not
so good for hitting pots.
It's a great feeling weapon, but it did take that edge damage.
All right, bladesmiths, now it's time to find
out how sharp your blades are.
This is the sharpness test, the dual sandmen slice.
Now, unlike the strength test, this
is all about what the edge of your blade
does to these sandmen.
Nick, you're up first. Ready for this?
Yes, sir.
[music playing]
[grunts]
All right, Nick, let's talk about your blade here.
As you can see, it cut the arms, cut the legs,
disemboweled the rice off the torso.
Overall, sir, it will cut.
Thank you, sir.
All right, Josh, your turn, sir.
Are you ready?
Let's do it.
[music playing]
[grunts]
[bleeps] yeah.
All right, Josh, this is a cutter.
Just a design of it really lends itself to really draw cut.
The cuts are very deep and they're very clean when
you're cutting through.
The rolling it took did not affect its cutting ability.
So overall, sir, it will cut.
Thank you.
Bladesmiths, the judges' deliberation is complete.
They've made their final decision.
The new "Forged in Fire" champion is--
Josh.
Congratulations.
Nick, your blade didn't make the cut.
Doug Marcaida is going to tell you why.
Nick, the zhamandao was designed to be
a horse slayer or chopper.
The amount of flex you have in your blade and the lack
of curvature made it perform less
than that of your competitor.
All right, Nick, at this time, please leave the Forge.
Come on forward, my friend.
I may not be the "Forged in Fire" champion, but by no means
do I consider myself a loser.
Congratulations, dude.
The sword that I made is something
that I am extremely proud of.
And when it came down to the decision,
today just wasn't my day.
Congratulations, Josh.
You are the "Forged in Fire" champion.
And that's a title that comes with a check for $10,000.
Come on forward and shake our hands.
I'm the "Forged in Fire" champion,
and I don't even know what to think right now.
It's something that I can show my kids that if you put
your mind to something 100%, you can
really accomplish something.