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
the most requested bill at this point by far Drock homie Hawks yodel which is known as the strongest
sword in the world this sword has many different processes so we're gonna get right to it we decide
to use the same 10:45 material that we make our large striking hammers out of John welds a handle
under this so that it's much easier for us to move in and out of the forge and on the presses
and hammers to begin breaking this giant piece of steel down we first moved to the hydraulic press
we repeat this process several times before moving on to the power hammer
with Ilya assisting him Sam now moves to the flat dyes to start
drawing or bleed out to link he then moved to the profile and then removed
the blade for one last heat to start refining the point to its final sheet
now that the blade is pretty much to length and shape Sam cuts off
his handle to flip it around hold it by the point and draw out his tank
in order to save me a whole lot of time while grinding this massive
blade Sam does some beveling with a hand hammer
I cut down a large block of pure graphite set it up and turn it on the lathe what I'm doing
here is I'm cutting some solid graphite I'm gonna make a mold that we can press the glass for the
pommel and the sword into using graphite forms Lauren does lamp work on the glass to create
the cabochon for the sword the glass is pretty forgiving once it all gets to temperature and
I can manipulate it for quite a while actually and then once I get the shape I want I'm gonna
flame it so it gets glassy once you don't have anything glowing you put the glass in here and
it'll keep it to slowly cool off once they're cool we're gonna cut them at the bottom and put
them in the kiln to anneal after doing the lamp work there's a fair amount of stress
in the glass it will have to be tempered it'll go into the kiln at room temperature be raised
up to 950 degrees Fahrenheit and then slowly pull over a minimum of six hours the blade
is so huge Kerry did a little hogging on the edge for me last night probably took four to
five pounds already I've got a four to five more pounds to go so I'm gonna start by just refining
the profile here on the backside a little bit on the edge and then I'll start my bevel
after defining the bevels and now move on to sanding the flat mat always seems to make this
look easy but grinding this huge blade took over eight hours of work and a whole bucket of sweat
with Ilya assisting him Sam removed the blade from the forge and places in the water for our quench
although Tim 45 is a water quenching steel it makes it a little safer it's still a huge
risk and no one at this shop is quenched ibly with this much mass or link before in
dole straight water they remove the blade from the water no king or King sounds that means we
have no cracks we didn't hear any pings or pops so it looks like this blade survived
the quench acquainted temper the mihawk sword in our regular hot oil bath in this case the
sword is actually too long so after it's been in temperature for a while we're gonna flip it
over onto the opposite side and allow the heat to crawl up we initially set out to create this
blade we were gonna leave the flat of the blade a rough Forge finish but in the anime it has a very
perfect black finish so we're gonna sand the flats perfectly and add some black oxide after
polishing to create that finish Sam's gonna be at this a while he's gonna be polishing the entire
blade most likely he'll be using two or three different Sanders with different grits on them
we decided to use some black oxide acid this is gonna turn a nice even black color I'm gonna keep
scrubbing it until it gets nice and black go back and brighten the edge and then it'll have the same
look like it does in the anime this is the wood core for our sword guard that we're going to cover
in brass later you can see I've laid my pattern out on this piece of ash and I've started to make
my relief cuts I'm going to finish now the cuts in the end and then we'll finish cutting her out
for the mihawk sword if we decided to make the god made out of wood and put brass leaf on top of it
the construction of a hollow gardening out of wood can be traced to mongol sabers of the 9th to 12th
century thusly i don't think it is inappropriate to make a huge guard that is unlifted well if it
were solid out of wood cover with brass billiad begins to cover the cross with brass he'll be
turning an edge and then using brass tacks to nail everything down we drew on some design work onto
the main guard using a chisel and a hammer ilium bosses that design into the metal first I use a
liner and trace the sketched out design the liner sets up and captures the material then I work from
the back giving the material some height and then work back from the front to give it more depth
I continue to attach the overlays using small brass nails it takes close to a
hundred of these nails to hold the overlays down using a chisel under
the fly press I'll and some design work on the land jets that run down the blade
since we made the land jets out of Steel I have to get them looking like the brass guard
so I heat them up in the Forge move to the anvil and use a wire wheel to cover them in breakfast
I take a large piece of 360 brass and drill through the center I tap this so that I can fix
it to the sword I then begin to cut the piece so that I can put the glass pommel in place
I place a locating flange on top of the meat Hawk guard this will be welded to the
core that goes down and holds the line Jets and then be nailed in the top on a massive
bleed like this it's actually difficult to figure out how things are going to go
until you actually assemble it I was a little concerned that everything would
be out of whack but we got it just right I think we did the greatest swordsman in the
world justice by creating this sword can't wait to see Sam try to swing it in the demos
and honor of made man's take your dad to work week we brought our dad to the
shop to show us how it's done a little more technique lets daddy show you have
that's it
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guys to build so tell us in the comments below what weapons you want to see next