I'm Matt I'm Carrie we are the stag my brothers a Baltimore knife and sword our work can be seen on
film Broadway and at renaissance festivals around the country we're going to be building some of
your favorite weapons in some weapons that you've never seen before this is man-at-arms reforge
looking at the comments in the videos we noticed a lot of fans requested this build think you guys
are trying to stump us we figured out a way to make this huge blade happen the build on
the berserk sword we decided would use 138 pound per yard railroad track Sam uses the oxy propane
torch to cut a cap rail off the track this track section will become the blade of the sword this
is the railroad track that we're using for the berserk sword we're utilizing a cap that we've
cut from the foot and the web that piece is about 55 pounds so the torch cut on the cap
rail is really rough so now we're gonna grind that so during the forging we don't get any
culture Sam grinds away right along the edge of the cut line from the torch baby-smooth we
don't have any tongs large enough to hold this piece of track so Sam welds on a handle that'll
allow us to control this piece of metal when it's red-hot and we have to move it around the shop
to reduce such a large piece of steel we take it to our hydraulic press we did the math on
the cylinder size and the pump pressure and it makes about 1885 tons which is just about
enough pressure to crush anything you can think of you'll see that we changed eyes
on the press this is done so that we can break down the bar faster by having a smaller area
that we're pressing on then we'll go back to a larger flatter area that will allow us to smooth
the entire piece making the bar easier for when we begin the blade work so with Carrie and Elias
help we've roughly drawn out the billet to its ruff dimension now we're going to do the final
sizing using a specialty dye under the press that has two half-inch stop locks as I want the finish
thickness to be half finished before grinding in the distant ater the half inch allows us to
size the entire thickness of the billet to an even half-inch over its entire length and then
we'll go back and take the width using the side of one of our other dies to keep everything even
and smooth using the treadle hammer setting on the iron kiss Sam cuts the tip off of the sword
using the oxy propane torch Sam takes the temporary handle off the berserk sword
so we've removed the handle so it's easier to maneuver into and out of the four into and
out of the press we're at the right length we're gonna spring fuller in draw the tank
now we've got the blade drawn out to link Sam begins to forge the tip
Sam make sure his bleed blank is straight and true before moving along to hand beveling
Sam's hand beveled hundreds of blades but I don't think he's ever tackled one this
big it's going to take dozens of heats lots of concentration and a whole lot of
strength to get this one done so you'll see Ilya do a lot of wet forging that's
a technique made popular by the Japanese here in America we like to do Tennessee wet forging
take a piece of 2 & a half inch diameter 12 L 14 steel and slice it down the middle to
create a fuller die and what we're going to do is blend this corner out here so that it
doesn't make a sharp shoulder when these get pressed into the blade hot this one
Sam takes the two pieces from the fullering die and welds a spring in between them making
a spring swage this will allow us to put the four in the berserk sword using the hydraulic
press just enough clearance in there to get it started but that it'll hold it firmly so that
I know where that fuller will be located on the stock using two and a half inch round fullering
dies Sam forges in the fuller in the center of the blade I will later on use a grinder to true this
up but he's gonna rough in the shape to save me a lot of time the double-helix Elda sword was the
most complex shape I've ever had to grind but this is by far the heaviest blade I've ever attempted
this process is gonna take me a couple hours so I move slow and steady to make sure I don't mess
up I removed about ten pounds of metal from this blade already still really heavy now that I have
my central fuller ground in the bleed it's time to do the edging the massive length of this blade is
a real challenge I brace the blade on my shoulder and slowly pass it down the grinding wheel
when we purchased the material for this pommel the idea is that we could cut it
all the shape and keep it nice and clean well this is Sam's build and he's a blacksmith that
just doesn't work for him he's got to have that piece hot and form him to the press
we are first approached about doing this build I made the boys a little bit said a
few guys can figure out how to forge it and get it heat treated I'll figure out
how to grind it maybe I should have kept my mouth shut the design of this furnace we're
using is actually called a muffle furnace it's a pipe within a refractory shell that insulates
whatever goes into the pipe from direct heat and flame keeps a nice even neutralizing
atmosphere low heat treating this massive sword is the riskiest part of this process
Elia and Kari used two supports to raise the blade up and lowered we LaForge lowered Gary
the berserk dragon slayer sword is so big that we have to fabricate a specialty quench tank
for it to be used in the hardening process John our head welder is fabricating that from a piece
of 16 square structural tubing so it's been about five minutes blades already starting to
glow we'll let it get a nice heat soak before we take it out for the quench whole step down
the Chairman so in far enough away okay then you guys live ready this is by far the most risky
process of the whole sword making this is the most dangerous quench we've ever done in the shop the
mass of this blade going in into the oil could be frightening oh this is the moment of truth
keep coming that's a good rate just keep coming we're good all the way down what
man I thought I might need my brown pants but I didn't Sam uses a bunch of scotch
brite pad stacked up on a hand drill to smooth out the finish of the blade
John cuts the pieces for the guard there'll be multiple overlays with lots of rivets and
everything has to look just right so the sizing is very important after cutting
the guard pieces to length on the saw John moved to the grinder to knock off the corners
using the mill John drills the holes on the sword guard this will be where we place our
ribbons so we're going to weld the guard on the berserk sword welding to high carbon steel that
railroad track tomato mix for some different problems that we have to deal with due to
the heatsink effect we have to preheat that so that that effect is lessened and then post eek
just the sheer size of this sword made it a very difficult build in the end I
think we created something that the black swordsman himself would be proud to wheel
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