The Fantasy Challenge - Forging the shark knife

foreign hey folks welcome to the channel in my fantasy  challenge build I wanted to go a little different   direction I wanted it to represent the  channel so here's what we're going to build   the shark knife and of course  it's going to be Mosaic Damascus   and we're going to have fun building the fittings  let's get into it here's our starting stack   you can see the black strip here let's get  it welded up I'm welding out the corners   of this Billet putting a little handle on  it and we're going to get it in the forage after a little bath and kerosene to Aid in the   Forge weld it goes in the Forge  to get heated up to 2200 degrees the Damascus I'm going to be making is meant to  replicate fish scales the graphic in the corner   is going to help you visualize what's happening  at each step here we're starting with this stack it's pretty much Forge welded now and  it's one solid piece now we're going to   start drawing it out with the drawing  dies and we want something like this remember folks the pattern you're seeing  is on the end of the Billet not on the top although it looks quick in the video each  one of these passes takes about five minutes   just a couple of seconds to forge it in the  Press but a couple of minutes to heat it up now that we've got the Billet in this shape  we're going to put it into the squaring dies   that's going to knock in the corners and that  will make the Billet look something like this after a couple of Heats with the squaring dies we  got it nice and square now we're going to rotate   it 90 degrees and now we're going to reforge  it flat and that's going to put these C's in it here's that bar cut up restacked re-welded  and ready to get back in the forage right now we've got this pattern we're going to   forge weld all the layers  together and draw them out after Forge welding we've drawn out this  stack a little bit again squared it up   now we're going to rotate it 45 degrees  and we're going to re-square it again   this is going to move that dark black line  and kind of curve it across the Billet when we're done re-squaring this  it'll look something like this here's the bar after our second forging session  remember the end looks like this now we're going   to take that bar cut it up into four equal  pieces rotate them and make it look like this   now it's time to forge weld those back  together drawn out into a Long Bar and   we're actually going to repeat this we want  a really nice fine pattern with small scales I put on the one inch kiss blocks here  just so I can get the Billet squared up   exactly to one inch all the way down then  we're going to cut it up again into four Let's do an update on our pattern we already  four weight it once to get this pattern now   we're going to four way it again and that's going  to make this pattern even finer and look like this yes folks we're going to be repeating this  one more time we're going to draw it out   four-way it again and that should give a scale  small enough that'll look good on our knife so here's our final four-way that's  going to take us from this to this since the pattern is on the end of the Billet we  need to forge this into a rectangular shape and   we're going to be slicing this up at 35 degree  angles so that's what we're getting ready for we've pretty much got this Billet forged  where we want it now we're going to switch   gears I want to do another stack here this  is so we can approximate teeth on the edge   of our knife so what I've done here is  taken five pieces of 1080 stack them up   and five pieces of 15 and 20 stack those  up and then put those two layers on top of   each other to make this Billet we're going  to twist this to create our teeth pattern now I'm just trying to get  this into a long thin Square   bar that I can twist in the twisting machine I've got this Billet down to three quarter inch  now it's going to go in the twisting machine I   got a foot pedal to operate this so it gives  a few spins and that'll twist it up for us as different parts of the Billet cool  at different rates that affects the   amount that each part twists so here I'm  just using some Windex that'll cool areas   that are too hot and are twisting  too fast so it'll slow them down foreign so let's take a look at where we are so  far so here is the Billet it's been re-squared   twice and I've sliced it up on 35 degree angles  also numbered all of them just to make sure I knew   which ones go where so now because remember our  pattern is on the end we're going to lay these out   just going to flip these over because  I've already actually done acid on one   side because remember the scales all point in One  Direction so they will be let's get this in frame   like this now I screwed up a little bit  when I did the last one and somehow got   it flipped around so this one the scales are  going the other way so I'm going to have to   slice this one and trim it here just so all the  scales go in that direction but that's not a big   deal so that's going to be our scale pattern then  we'll put those we'll weld all these together with   mild Steel on either side just to sandwich them  all so that's going to be our next operation   so after that's all welded up we're going  to put an edge bar on here and I want it   to look like teeth so you saw me  Forge weld this guy and twist it   um I'm not thrilled with how uneven The Twist  is it's nice and tight here but it's a little   wider here and here so I'm actually going  to end up reheating this um heating up the   end twist it and heat up this end and twist  it just to get this a little tighter so they   they look a little more even and that's gonna I  mean and it'll be a thin little bar underneath   and now it's going to act like my teeth and  hopefully that looks okay um you know they're   kind of it'll be black white black white so  they'll kind of look like teeth so now I weld   up all those tiles onto some sacrificial  steel just to keep them all together and   Forge weld them up that'll give us a nice solid  Billet and that'll be the basis for our knife hey folks I want to take this opportunity to  remind you that this is a challenge among a   whole bunch of YouTube channels now I'm one  of the judges along with four other channels   but the other 20 channels are all competing  for your votes so it's important that you   vote for the channel and the build that you  like the best I have a link to the voting   survey down in the description so make sure  you go and vote and watch all of the builds   I also want to take this opportunity to thank  our sponsors these guys are donating some amazing   prizes for the viewer portion of this challenge  so stay tuned you'll see an announcement of who   the winners are and thanks to these guys links  to all them down in the description as well   and now the tedious task of grinding  off all that sacrificial Steel then we're going to take our teeth bar and  we're going to weld that to the side and   reforge that into our final Billet that  we're going to shape the knife out of anytime you have an edge bar that  has to match the curve of the blade   you can't just cut the blade out of it  so here I'm forging the blade to shape time to reference our pattern again just  to make sure we have the right dimensions now I'm using the press to put the  ricasso in and start to draw out the Tang all right so here it is after forging um the  camera overheated so you guys missed a little   bit of it but the edge bar is here remember  this blade is going to have a down swept   um a curve to it it's much longer  than originally planned so the blade   if you go like in a straight line  is about 16 inches if you were to   yes yeah it's about 16 just over 16 inches so  now what I'm going to do is surface grind The   Edge because I want to see exactly where that  edge bar is because I want it to be a constant   thickness I don't want to start grinding any of  the profile because I don't want this to look   narrower in one spot and thicker in another so  let's surface grind it and see where we're at so here it is after surface  grinding and a test etch   turned out pretty nice the uh  The Edge Bar is pretty even I like it so now we can just take  a little bit off this Edge Bar   I can see it's just a little I'll have to just  drop the point a little bit but uh it looks good okay so let's talk about the design a little  bit so there's going to be a bevel a big bevel   here so pretty decent bevel on both sides okay  there's going to be three notches these are   going to be kind of this part's going to get  removed I was going to put a big dorsal fin   on the top of the blade but that just seems  problematic so the dorsal fin is actually   going to be part of the Guard so the way it'll  be something like this more of a point here   and then down here there's another pectoral fin  that comes down something like this and then into   the handle and then this so this is going to be  kind of straight and it'll be a little bit over   so it's kind of hover over the blade and there'll  be a blank spot under it so I think that's going   to look kind of cool I might actually go to here  and the blade is going to fit into the guard   so I also want a false Edge on the top and the  false Edge is going to just meet up with this   first one so the first thing we're going to do  is grind this false Edge to be about that depth foreign so here I am at the Mill putting  in those notches on the top of the   blade yeah I could have done them  with the file but hey I have a mill now it's time to put the  bevel on the knife this is   just our pre-heat treat bubble  so it's only about 80 percent so here it is after initial grind   um you watch me do the uh these little notches  in here so pretty happy with it it's pretty mean   looking Blade with this forward curve in this  point on it uh so it's really cool I'm looking   forward to seeing it finished now it's time to  do the heat treat process and then final grinding well as what happens sometimes in knife  making things don't always go as planned   so the Edge Bar I guess was not Forge welded  as well as I thought during the quench it   developed a little crack here and then um I  wouldn't even see a crack a tiny little seam   and then after temper uh it was a visible  crack in the seam so I just snapped It Off   and now we're gonna have to make a narrower  blade and maybe a little shorter so   they always say bladesmiths don't make  mistakes we just make smaller knives   well on the plus side I did snap this just  to see what the grain looks like and it is   nice and powdery so the heat treat was spot on so  now I just spend some time reprofiling this knife   making it a little smaller it actually works  out really well and I like the final outcome foreign so here's the blade after final grinding I'm  pretty happy with it grinds are nice and even   comes to a pretty fine Edge I've  never done a false Edge that goes   this way usually they swoop the other  way so it was an interesting one to do   now I just gotta hand sand this and then  we'll start on the guard so before I do   anything else I figured I would check the  the hardness of this so let's give it a shot and here goes so that one says 59  and a half let's do it one more time yeah 59 and a half exactly all right  59 and a half HRC for this blade so here's the blade all sanded to 800. it's  come out really nice I like the lines on it   so now it's time to turn our Focus to the guard  here so the way I'm going to end up doing this   is I'm going to do this Central piece here slot  the slot the guard fit the knife and then take   off a bunch of material here and then I'm probably  going to end up welding on these guys afterwards   so we're going to start with this which is  quite thick because you'll notice this has a   the knife is inset into the guard so we're going  to do that so we need a pretty thick piece but   most of this is going to get ground off all  right so let's go to the mill and Slot it so I wanted to show you guys  where I'm at with the guard so   I've got the guard slotted you can  see that um I've slotted it this way   so that it kind of goes up here I can get  it back on um and then the fins I've milled   the top slot so the fins are going to go  inside I'll just put them so it'll be like like this and it'll kind of hover over  there and then the bottom fin will be here   then what I'm going to do is I need to take this  down a little bit but then I'm going to weld in   these and then Contour the  whole thing so it matches time to work on the handle here  I'm going to be using this piece   of tiger Maple because I think that's  going to look pretty good against the   shark theme so we're just going  to drill out the hole for the Tang foreign Maker's Mark in get that all nice and etched  and then we're going to etch the blade I decided the fittings and the handle  should be blue so here I'm using hot   salt and we're going to immerse the guard  and the palmoline here to turn them blue   and I'm just going to dye the handle blue as  well so I think that should look really cool are you guys ready to see  this all put together foreign foreign foreign

Channel: Tyrell Knifeworks

Views: 172,358

Keywords: The Fantasy Challenge - Forging the shark knife, tyrell knifeworks, shark knife, the fantasy challenge, forging a shark knife, fantasy challenge, mosaic damascus, shark sword

Id: -6gr7_NRaJk

Length: 27min 45sec (1665 seconds)

Published: Fri Oct 14 2022