Forging A 20-Pound Mind-Blowing Damascus Sword

🚀 Get all the tools and materials I use through my free PDF 👉 www.learnknifemaking.com/mast...
Join us on an epic journey as we embark on the creation of our most ambitious project yet - the "Griffin" sword! This legendary blade, inspired by the mythical creature, will take approximately 7 months to craft and will be the most intricate and advanced sword I've ever forged. Follow our progress as we meticulously design, forge, and perfect this awe-inspiring sword, and witness the birth of a true masterpiece. Don't miss a single update on this incredible adventure - subscribe now and be a part of the "Griffin" sword's story!
Get the Griffin Sword Tee: 👉 royercutlery.com/merch
Watch pt. 2 • Shocking Reveal: My Fo...
Watch pt. 3 • Unveiling My 53k Layer...
Watch Part 4 • Sword Break or Bend? Q...
Learn how to make knives: www.learnknifemaking.com/
KZbin ~ / kyleroyerknives​
Instagram ~ / kyleroyerknives
Website ~ www.kyleroyerknives.com/​

[@James-bw4np]

If i win the lottery, I am commissioning a sword from Royer! The quality of his blades is out of this world!

[@theviewer9363]

Me too 😅

[@NineteenEighty8]

Been my plan for several years now. Still haven't hit the lottery lol.

[@Tom_Emody]

Same here my friend. Good luck getting one of his blades. They are pretty rare considering how long each piece takes to create. …Tom

[@James-bw4np]

@@Tom_Emody the wait would be worth it! His blades are works of exquisite art!

[@justinattakai5167]

...YESSSS! LIKEWISE! DUAL EDGE, DUAL SET, MOSAIC DAMASCUS NINJA SWORD! WITH MATCHING GEAR.

[@nagamata]

I love how no one in this family takes themselves too seriously but the quality of the work is seriously incredible. If you showed someone just one of Kyle’s pieces, they probably wouldn’t think it was made by a guy who said “Drew Berry….more power.” It’s a beautiful reality.

[@povilaskairiukstis9577]

As a person who once spent way too much time making a nail in the forge from 1800's, I can just admire his work ethic, attention to detail and sheer hard work that this man puts into his projects...

[@sjaakzwart6001]

These pieces will be admired for the coming 1000+ years.

[@bennyb.1742]

The cockroaches and racoons will have great taste!

[@jamestetley180]

Not at all. A dude brought it and it’s never to be seen again.

[@sjaakzwart6001]

@@jamestetley180 He takes it withhim to his grave?

[@okme6998]

Yes because that's all you can do is look at something that weighs 20Lbs He shouldn't be making this it's a mockery of his craft StupidStupid

[@LeirbagFR]

@@jamestetley180Satan hates you

[@rcg3496]

So much patience, so much creativity, so much imagination, so much attention to detail; and sooo much talent..!

[@rodmorris9690]

All that AND.... soo sooo soooo soooooo much of effort!!! Labor intensive cubed.

[@manditrrr]

and sooo much complaining "its too hot, oh its too heavy,x100"

[@erikcourtney1834]

I put a layer of bubble alumina refractory (flux resistant) over my castolite refractory. Only on the floor. I haven’t had a problem with any flux since then. before I did the relining i found that laying a stainless steel plate (with a slight concave shape) under the billet inside the forge solved the issue also. Then removed it after the welding is done and gave the billet a good hot brushing to remove any remaining flux. Hope some of this helps with any emergency fluxing problems anyone has.

[@plectrumura]

I’m super glad to see another major build video. As someone who has been bladesmithing for about 4 years and is in the process of outfitting a new shop after a cross country move, these videos really inspire and motivate me. Good on you all, Royer family.

[@samdahlandsonsforge]

Kyle, Your dad did an awesome job on the new forge! The one thing you might notice if you have un-used burners that are still in place in a multi-burner venturi is that they will have the hot heat seep up through the open holes and it can melt the unused burners or connecting lines. I have seen some people install a rotating blocking mechanism inside the chamber or even a ceramic hole cover between the connection to prevent this. I hope you don't have melting pieces like I did!

[@BH-rx3ue]

yes, YES, YEEES! Time for a sword to be Royerficated! I cannot wait to see how this all turns out

[@ClenioBuilder]

👏👏👏🤜🤛

[@andrestein6022]

This channel is one of the most masculine topics taught by one of the most wholesome people on the internet lol the juxtaposition is crazy

[@ASMRwoodworkin]

I love these videos. I watch them start to end.

[@squidikka]

Grats on 420k subs, certainly a high achievement!

[@Michel411]

Subtly done, bravo.

[@MayotheMaker]

Your positive attitude is really encouraging:) I love tuning in for these builds, thanks for taking the time to film all this

[@mnjmedia1707]

MY MAN! I have been waiting for a new vid and you drop THIS on us?? An hour long massive sword build!! Now I have to stop working and watch it... twice. Love your work, brother!

[@jimcorbett3764]

And this is why there are so few really good bladesmiths.

[@is44ct37]

I like how they all have the same jokes, they are like clones

[@PrettyHateMachining]

Awww, it's gonna be so petite and adorable!

[@rodricbr]

here comes another masterpiece from the master himself

[@shk2564]

When I was in high school I was in the Industrial Cooperative Training Program and worked as a welder in a shop that made carpet cutter machines and spent a lot of time welding rollers onto shafts and the frame that they bolted onto. One guy would slowly turn them as the other ran the bead around the shafts. The first time I spent hours turning I looked too many times or just didn’t turn my head far enough away and burned my eyes. All night it felt like I had sand in my eyes and my eyelids would stick to my eyeballs and water would pour out. It was terrible! I did learn a lesson I have never forgotten and until this day (40+ years later) I close my eyes when I see anyone start welding in videos! 😂

[@IYIENACE]

I love the family affection! I wish I'd shown my Mom & Dad more how much they meant to me 🥰

[@notsure9137]

YES!!!!!! I cannot wait to watch this and see the finished blade. I still go back and watch the other two sword builds every now and then.

[@frankierzucekjr]

This is going to be awesome. The new forge is so cool. Love that the whole family is involved and everyone is so loving. Can't wait to see how this comes out.

[@hancockheritageknifeco]

Best way to start the weekend is with the Royer Family 😎

[@frankierzucekjr]

Agreed

[@stan4d1969]

You lost me with the lettuce on the pizza. 🙂

[@ConanDLibrarian]

"Is that legal?" "I will MAKE IT LEGAL!" I dunno why that quote has stuck with me for so long

[@jonballard4453]

Dude! BLT pizza is one of my absolute favorites that i forgot about completely.. so thanks for reminding me.. And, of course i love.your work and craftsmanship and Autine Grade precision fit n finish. Watching you continue to up your game everyday is very inspiring. You truly live the dream imo, your family being seemingly totally united and laser focused on a central objective and its such a blessing .. I love that your dad not only facilitated and prioritized his sons interest till they became a dream then a reality, but now hes well on his way to MasterSmith and so far as I can tell is working professionally as a knife maker both with you and solo. I applaud your father for his commitment and hard work ethic . I hope one day i can be that with my own son.. love the channel for sure, keep up the good work.. Thanks

[@chrisangelone3349]

I am so excited to watch an hour long episode of Kyle Royer. I wait and wait for your KZbin episodes to come out. You always blow my mind with your amazing creativity and skill. I truly feel your knives and swords will be in a museum some day. I’m ready to watch this one

[@ololadin91]

Oh wow - as a German I can't say how often I thought to my self: 1.) damn - that doesn't look safe! 😬 2.) wear your protection dude! 🙈 3.) wtf!?! He built those machines him self?! Is he quallified to do this? 😱 I just can't stop laughting about my self 😂😂😂

[@frankierzucekjr]

In America, we just found what needs to be done, bud. He's definitely one of the safest I've seen.

[@ololadin91]

@@frankierzucekjr 😆👍

[@CorbinMusso88]

In America, we go by the “safety third” policy. If it gets the job done, a little danger is acceptable.

[@Crazyclay78YT]

another one of my favorites is "if it aint broke dont fix it" as long as it works, keep on going

[@Justin-zw1hx]

This is what we call, Redneck

[@KC-oh1oh]

I do not usually find myself making comments on KZbin as I feel it is not necessary, I do however need to communicate how much I enjoy watching your masterful work step by step forged and fitted. Thank you!

[@JacobE-23]

It's amazing to watch.

[@nilsdasberg7916]

I am so Happy to See a new Swordjouney on your Channel, i totaly Love your Work and your positive Energy.

[@samsham8218]

WOW!!!! I CANNOT wait to see this!! Kyle makes THE MOST BEAUTIFUL Edged weapons. His attention to detail is Astounding.

[@KeiPhillips-sy8by]

Wholesomeness, mastery and chaos = The Royer family. Loved this vid so much guys, can’t wait to watch the next!

[@classicmula]

That’s awesome to see the amazing relationship you have with your family. You are blessed sir. I praise your work.

[@NineteenEighty8]

I'm going to program a CAD-like application so you can design damacus patterns and knows all the steps you need to take to achieve whatever pattern. I know tons of bladesmiths would love this.

[@ramonpizarro]

That is a great idea You will have great success with this, I have no doubt

[@NineteenEighty8]

@ramonpizarro Thanks brotha'. Already talked to my dad(better programmer than me) about this and he said the same. We are already spitting ideas out and making plans for this. Cheers!

[@howardpayne4128]

I've worked as a pipe fitter which entails using a grinder all day, let the tool do the work. As the weight of the machine is enough to do the work and holding it at the right angle will make it weightless. Adjust the angle of what you are working on to lighten the load.

[@Danmik8833]

Kyle, you're unparalleled mastery of the art of forging coupled with that unique sense of humor absolutely shows in every video and also every piece of art you create. Thank you!!!

[@mtnbkr8480]

I just started watching this video but I already can't wait for part 2. 👋

[@nplillustration]

That family time and love shining through at the end got me right in the feels. Great video!

[@gorillapup3387]

Ever try making billets of 3 different steels, draw it out into rods, then braid them? I'd love to see the Damascus pattern they give off, especially with as meticulous as you are! Love the work you do, keep it up!

[@corey2477]

really enjoyed seeing your family with you and how smithing brings you all together.

[@cletusblue]

I’ve been working with Medal and welding for 50 years, but don’t get me wrong. You’re a master, but a leather work apron will keep the heat off your legs. I also use sunblock, and I do wear a face shield when exposed to extreme heat like that. I am glad to see you using water to cool the metal when you surface grind . I am probably your biggest fan, and now that I’m retired. All I do is forge mosaic Damascus.

[@chrisjvales2]

The "grind" is real. Ha got me this morning. This just made me want to go to my garage and work on a knife. Still new but gave me some inspiration

[@AdoreYouInAshXI]

It's a very good thing you're so unbelievably talented to be able to create such masterpieces, because your comedy is sorely lacking lol.

[@Tom_Emody]

It warms my heart to see your family goofing around together. That’s the best part of life. ….Tom

[@BolFelix]

Im not kidding, I studied history and always was interested in wars and weapons and stuff like that and the 2 swords you've done so far could honestly have been done for generals/royals. Of course it's an unfair comparison because their equipment wasnt the same at ALL back then, but he's all alone doing this. Insane!

[@gameface8080]

This is going to be an amazing series. I can't wait to see it finished, but the journey will be just as satisfying.

[@justinsmithing]

20 lbs.?! Jesus! I thought that my sword being 4.5 lbs. right now (unfinished) seemed heavy lol. I love watching your videos, I hope someday I'll be able to have the setup and time like you have to do more. I'm making my first sword ever and I'm 8 months in with extreme attention to detail lol. Nothing has gone catastrophically wrong and everything is coming along as planned though!

[@danyboyg1535]

The most beautiful sword I have ever seen was made by this man, I can't wait to see how this one is going to turn out

[@Oikolukuhirvi]

Kyle needs to get a smith's apron to combat the heat and a wheelbarrow to move the billet around :D

[@ronjennings1453]

I really can't wait to see the finished blade this time! This might be my new favorite KZbinr Sword

[@sebastianmarquez3014]

Right on Kyle, happy to be along for another ride 😁

[@truthbetold7718]

Kyle has made some of the Greatest blades ever crafted but my absolute favorite was the purple feather Damascus folder. 😍

[@motou1]

Dude your parents are amazing that hug and kiss man made me tear up your a lucky man !!

[@bwell6863]

Me too!

[@mayhem1988]

When handling big billets like that I use a hook made from bent up 3/8 bar to support the handle way closer to the billet than you could put your hand without burning it. The largest billet I've worked was around 25lbs and without the hook it really strained my back, but with a hook it was fairly manageable.

[@davelewis6093]

So glad your doing a SWORD again!

[@theallseeingmaster]

When you finally deliver the blade to your customer, does the customer get the original sketch along with the blade?

[@danieldaw1778]

I love how they all have the same sense of humor and did the same bit with the billet.

[@pappaal]

You're incredible dude. Blown away at your craftsmanship.

[@TheMeditron]

Man, excited for your next projects, they always come out so beautiful.

[@VinceW187]

Amazing gatehouse, looking forward to the rest of the build in this style

[@johnperez3212]

Getting a Kyle Royer’s sword is like getting a super limited edition custom made rolls roice phantom. This are one of the fewer long videos i would not mind watching complete

[@TomElliott25]

brilliant as always 👏👏

[@shepardsforgeh2031]

Dig the longer content man! I know what goes into a build like this! Well not personally but thanks for showing us!

[@adambrunius5158]

Kyle, you are amazing. Everything you make is a masterpiece. Also, I was thinking: You need a Kyle Royer bobble head. You bobble so much naturally it would just make sense. I would buy one.

[@dwyanejetersr6470]

You are a master of sword making. PHD in sword making, enjoy your work and extraordinary skills. Creative to the nth degree.

[@calumleggett8292]

I love this man the absolute pinnacle of skill a human could hope to attain

[@manueldiez2929]

Que grande Rojer miro todos tus videos y sos para mi un ejemplo a seguir muy profecional saludos desde Argentina !!!🇦🇷🇺🇸

[@chweissinger1]

Wow guys! What an awesome build! Thanks for bringing us along for the journey! Would love to see a video of the build process for the new forge/ working review of the setup. Keep up the great work!

[@anderssorenson9998]

Thank you for making me feel better about my welding.

[@mr_doublebutt]

I'm so hyped!!! Your work is always so beautiful!

[@luciomarx]

Can't wait to see the sword!!!

[@philipejeuceoututkache]

You've done crazy things over the years Kyle, but this, is something of another level. good luck, as this one won't be easy ^^

[@6Sally5]

The complexity of tracking the damascus pattern just is mind boggling!

[@luisdacosta1541]

Your a very lucky man. I can see how dearly you treasure those memories... I wish I had the time go back to create them whit my dad.... I'm loving you video,,just paused to comment.

[@OGCHOOK]

The most badass nerd I've honestly ever seen. And I say that with the utmost respect🙏🏽

[@angvannuil9280]

Dad did a great job with the new forge ....big job ahead can't wait to see the end result,,,Angie in Scotland

[@jesseokonczak7963]

Ok I've never bought merch from KZbin but that griffin holding sword shirt is sold!

[@scottlarkin4748]

I love the slow-mo of the press

[@leondumbarton9126]

Freshly cooked video no way! I've always wanted to try blacksmithing!

[@osirisatot19]

I know Kyle has been doing this for a lot longer than I have, but never leave anything resting on a machine that is on, especially one that spins; and loose clothing is also a bad idea. I also hate using flux for the same reason, I like to put fire bricks on the bottom of my forge to keep it from needing repairs as frequently. I'm super excited to see this incredibly intricate pattern once the sword is done.

[@tdg911]

I cannot wait to see the finished product. The videography is better than discovery channel. Amazing job Kyle (and team). True master. I love watching the content here.

[@trxcummins7388]

You know what would be cool if you can make a takedown sword and make the Tang really artful with possible filigree or diamonds or gold inlay. It would be kind of like a hidden signature in an art form.

[@AwakeAtTheWheel]

YES!!! We’ve been waiting for this one! 🍻

[@anglerseawolf9919]

Something u might try is coating the bottom 1/3 or so of your forge with bubble alumina. It will protect it from the borax or whatever flux u might use. I put it in mine and it seems to work well.

[@fliplmb]

Looking forward to the inevitable claymore 👍

[@RobertSmith-ce5wk]

The fact that swordsmiths would do this work with nothing but a hammer and anvil is amazing to me. They must have been hulks.

[@yvonvoyer5812]

This makes me want to get back into sword smithing ❤

[@andrebolden7686]

Absolutely enjoyed watching this video. I thought Forged in Fire was the pentacle of knife making... I see I was wrong.

[@davidcanoy8579]

Good fortune. I am looking forward to watching these builds.

[@kwbknives7989]

Excellent video as always! We used a 9" grinder a lot but recently switched to Pferd seel+INOX disks on the small grinder, they are amazing, go through forge scale with ease and saves your back.

[@paullambert4445]

Wow! What huge pieces of steel. Thanks 🎸🔪

[@nickzeigler3134]

Put a chain support looped into a roof beam in front of the press and forge (or use an A-Frame for the forge). The chain will take almost all the weight, keeping your shoulders healthy, you farther away from the billet, and you'll be able to swing the billet into the press at whatever angle of attack you choose. If you want to get fancier, you could run a chain hoist on wheels on I-Beams to help carry the assembly around the shop.

[@broman6662]

Love your videos, and how you love and respect your parents!!!!!

[@heavycloud9545]

Your swords & knives are out of this world I’ve never seen such quality your blades look like legendary weapons, if I ever get enough money I’d love you to make one for me as I’m from the UK

[@brunobarks6544]

This is gonna be awesome !!! Thanks again 👍

[@JiryStark]

As a professional welder I cried in AGONY from 10:54 to 11:35 lmao

[@broman6662]

You little amazing nerd( And when say Nerd, its a compliment!!!) blow my mind in every video! I love it!!!!!

[@christianjeffress5312]

Always love to see your beautiful creations

[@dplagoon]

I'm excited to follow yet another project from @KyleRoyerKnives. I am always amazed at the attention Kyle gives to the smallest of details. It's almost inhuman. A team of a thousand super knife making nanobots couldn't do a job as good. Good luck on the sword!

[@redgreenblue998]

I will use a sacrificial steel bar or plate to protect the base of my forge When using borax. Stainless last the longest but I don't think burning chromium is good for us. Mild steel 1\4 inch thick will last several forge weld sessions before it becomes too thin. Great content!