I'm Matt I'm Kerri
we are the stag my brother's a 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 this
episode we're finally gonna make pyramid
heads knife from Silent Hill now there
are a couple different variants of this
knife in the games in the movies we're
gonna make the one that looks like a
giant Rambo knife it's gonna be a little
more flashy we're going to show a little
more skill in that so we're going to go
ahead and get to making that Silent Hill
it takes place over a coal mine so we
thought it would be a nice tie-in to
make our blade out of some train track
to kind of mimic that mineshaft
operation and give us enough material to
make this giant blade out of sofa
pyramid heads knife we took the top of
the train track the track part of it and
cut her off the bottom it did a little
bit of pre forging on it I have to be
wearing a lot of protective gear because
this amount of heat radiates up to the
blacksmith resulting in the possibility
of injuries and burns especially on the
arms you'll take me a full day to widen
it and extend it resulting in a preform
of the knife
the first step Illya is doing is drawing
out the point the shape of this knife
blade has something called a clip point
much like a bowie knife just shaping
that point and then he'll draw out the
rest of the stock to link them with
obviously every day we can't practice
forging these giant bleeds but Ilya does
a lot of practice on normal sized bleeds
that allows you get the process down so
when we go to make these giant blades we
have a really good idea where we're
going and we're doing a pretty good job
we'll get everything refined as we go
and we're just gonna keep making this
thing bigger and bigger and wider as we
can and hopefully be done soon
because of the size and the weight of
the blade I needed Matt to assist me one
major problem is that as he forging it
the weight of the blade itself forces it
to droop over the dies that creates not
only a dangerous situation but
interferes a lot with a forming second
thing is in order to use the full ring
dies in the power hammer I need a person
to assist me on the other side
stabilizing the piece the following dies
birth by pinching metal normally the
four is pinched into the piece however
if you use a series of consecutive
followers each one deeper than the next
one and each one infinitesimally close
to the previous one you produce a bevel
alright now we got a lot of the blade
forging done what we need to do is I'm
gonna go to the chop saw cut off the
handle we have welded on and then we're
gonna be able to hold it by the tip and
do some of the forging down by the Tang
in the shoulder area
all right now that we got our ricasso
area formed which is the area between
the shoulder of the blade in the edge of
the blade now we're going to go to the
very edge of our dies on the power
hammer and start pulling out that plunge
grind look to the edge we now have the
blade pretty much forged the shape we
just have to scoot that point over a
little bit I'm going to do this by
heating up that point specifically and
slamming it on the anvil and when I'm
done it'll have a little bit of crinkle
illy old hit it with a sledgehammer
we'll go back repeat the process a
couple times until we get the material
where we want it now that this blade is
to form we notice that the Tang needs to
be a little bit farther towards the back
I'm going to hold the blade while Matt
and Ilya strike and push it down to
where it belongs the last few heats that
we're gonna do in this massive blade
before grinding is getting it nice true
and flat we're gonna use a flatter I'm
going to direct Ilya where to strike to
get any bumps or lumps that could be
left in both the bevel and the flat of
the blade
all right you guys got the blade here
rough forged out I'm going to get head
use our hand plasma torch and cut the
cliff point off four and make a little
easier on the grind
here I carefully remove some material
from the edge and the spine to create
the desired profile before heading
all right we have our final shaping done
on the profile of the blade it's time to
start edge grinding in the game the edge
has a really narrow plunge grind on it
we're gonna do a little more realistic
edge on this great knife give it a
better chance to cut things well in the
demo so I'm going to start on our 12
inch wheel here and just do a hollow
grind on the edge gonna take me a little
time but eventually it's gonna pay off
I've tackled some pretty big blades on
man-at-arms so you know that I can do it
but sometimes size really does matter so
I called in bill to help me out on this
he's gonna hold one edge as I grind the
other
all right now that bill and I have most
of our edges roughed in I figured now is
a good time to take a break and start
laying out where our backs are Asians
and our folders are gonna go the back
serrations and the fuller both start at
the ricasso area and work their way up
the blade I counted in most the designs
about nine serrations and the fuller
goes all the way almost to the false
edge if you ask 10 different blacksmiths
or bladesmiths how to put a fuller in a
blade they're probably going to give you
ten different answers in this case I use
a two inch wheel and just freehand it to
shape now that my fuller is grounded
it's time to start on the serrations
normally I would just grind these in but
I got to be honest I'm pretty tired
after all this grinding so I'm gonna use
the hand plasma rough in my notches and
then move to the grinder to true
everything up
now that I've roughed in my notches on
the back of the blade I'm gonna go ahead
and throw them up with a hand sander the
difference between hand grinding and
using the Sanders like I usually do is I
prefer to move my work to the wheel in
this case I'm moving the wheel to the
work it's a little different gotta think
about things before you get going but
it's going to save me some energy and
I'm gonna go ahead and get at on the
Silent Hill blade we've got a really big
knife kind of has a bolster more than a
guard it's kind of a big block of Steel
that goes on there so we've got to make
a pretty big slot in this we're gonna
put it on the milling machine slot where
it goes all the way through for the tang
and then slot a shoulder that the rest
of the blade can lock into to give it
some strength
okay so once again we're breaking out
the old hobo furnace of doom for this
heat treat basically what this is is a
couple electric kiln rings with a KO
wool lined barrel we're firing it with a
giant weed burner powered off the
propane it gets plenty hot it's going to
heat up to about 1550 degrees in about
10 minutes our goal for this heat treat
is just to get the edge he treated so
we're gonna heat that up quench it
horizontally and let it sit there and
burn out for a while because it's gonna
flame big and it's gonna flame for a
long time
well that's about the edge quench from
Hell right there this part was not
quenched at this point the heat that
this thick area has retained will start
creeping back on our edge and kind of
self temper we're still going to play it
safe
well temper it again but that's the
whole idea about doing a big thick blade
like this we noticed that this wicked
blade always is shown with a lot of
battle damage scars
big scrapes on the side of the blade so
Illya uses an angle grinder to grind
knees in gives us the look we're looking
for and now we're ready to finish it up
this blade has an obvious rough Forge
finish in the game so we're just going
to give it some highlights and some
flash on both the surface the Baxter
ations
and the edge
now ready to begin the handle
construction what we're gonna do is we
got our guard here steel bolster and
what is going to work as our steel
pommel aka our counterbalance for this
giant blade not gonna work what we're
going to do we're going to do a Purple
Heart handle I'm going to lay the piece
of purple art here trace the Tang cut
two identical pieces out make a sandwich
glue it up pin it form it and then we'll
have our handle Purple Heart is called
per bar cuz it's purple it's a very
dense heavy wood I don't care if you
don't like it it's my favorite wood
carries maybe stuff since I was a little
kid for my birthday and Christmas he
always made sure without a Purple Heart
just think it's really nice wood and
it's gonna work very well as a handle
for this
with the Purple Heart already fitted to
the tank Matt fills it with epoxy and
clamps everything in place until it
dries super happy with this sword turned
out awesome the forging was great the
grinding was a challenge I think you
guys are starting to really just not
like me requesting all these giant
blades knowing I have to be the one that
grinds them pyramid heads one of the
most iconic faceless villains in any
video game ever I think we did him
justice just excited to get to swing
this thing
and and
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