Unveiling My 53k Layered Damascus Steel Sword

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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!
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Watch pt. 1 • Forging A 20-Pound Min...
Watch pt. 2 • Shocking Reveal: My Fo...
Watch pt. 3 • Unveiling My 53k Layer...
Watch Part 4 • Sword Break or Bend? Q...
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Website ~ www.kyleroyerk...

[@stevenofalltrades8553]

Your craftsmanship is other worldly. If you didn’t ever say anything and showed only the project I would watch obsessively. However, your mini bloopers and family involvement shows us who you really are and makes your content just absolutely outstanding. I love getting to know you guys. Keep up the good work and keep being you. Love it!!!

[@phillipstrauss6269]

Very welll said. Many people share your sentiment

[@Phuquefull]

Watch his dads videos, thats how they are. They're perfect lol just work, no corny words

[@markcalvert7601]

Wellll there's a little corny here and there, but it's authentic corn right off the cobb. It's always fun!

[@gameface8080]

I just want to give a shout out to Josh. Your camera work and editing has really improved as much as Kyle has with knife making.

[@tomspooner3436]

I was honestly thinking the same thing I really like how he has the current project showing through in the master Smith's guidebook advertisement

[@danielstellmon5330]

No one notices good camera work and editing, every one notices bad camera work and editing. Well deserved shout out.

[@KyleRoyerKnives]

Awe thanks!!! ~Josh Royer/Kyle's brother/camera guy/editor

[@toknowwhyuneed3593]

I watched an older video as one of my first videos on this channel and didn't notice the date. I talked about the issues with editing and this video, now I'm checking the dates, is much newer and all the old issues I had with the editing are gone. This is exactly what I wanted! I love learning about his work and seeing his dorky personality. It's just great. I hope that more people enjoy this new style for his channel.

[@OzMate79]

@@KyleRoyerKnives would your sword have more strength if made from one piece of ore?

[@Emponix]

Imagine if people around the world would put the same effort into doing good for other people. Kyle is just an amazing human being. Also that pattern is gorgeous of course.

[@tdg911]

Well said.

[@jonesy77777]

Imagine the impact if just you practiced what you preach

[@mementomori4972]

"doing good for other people", "amazing human being". You understand this is commissioned work for a paying customer. His Excelsior sword was $65.000,- Are you delusional? This is a luxury item for a rich collector. His knifes are around $10.000.

[@-MrFozzy-]

@@mementomori4972yeah I was incredibly confused by the comment

[@tdg911]

I no longer have any words to add for these insane knife builds. That pattern is absolutely gorgeous, bravo. A true maestro and master craftsman. Lets not forget the videography here and team work behind the scenes (mom, dad, sister). I don't even make knives or collect but I love watching these videos. The passion for excellence is like no other. I cannot wait to see the final product. Much gratitude for sharing these videos. I always walk away from them learning something new each and every time.

[@mikekooz475]

Surface grinders use a diamond dresser. It’s industrial diamonds mounted on rod that is mounted to a base. You magnetically stick the dresser and carefully run the wheel across the dresser tool.

[@strangereyes9594]

Right. The reason why his method produces such an "aggressive" grind is just that it whacks the wheel unevenly and leaves it all jacked up like his broken grinder disks. If he is not about flatness, then sure, it works better than a nice and evenly dressed wheel with a diamond tip just because it leaves more sharp stone edges on the wheel.

[@Randefelt]

I work with grinding, mostly centerless and centerd grinding, some out of round and surface grinding as well. The trick to get the wheel to cut as well is to find the right depth and feed of the diomond across the wheel. 10-50 microns per pass and 1-5mm/s across the wheel, faster and deeper dressing of the wheel often result in a more agresive cut. all depends on the mate rial and type of grinding wheel. I mostly use 80 grit 3m cubicron wheels. The surface grinder we have at work have a hydralic dresser on top of the grinding head.

[@jvbknives]

What a good day when a video from Kyle Royer is posted!

[@Joe___R]

General, you don't want to rough up a stone on a surface grinder. If you want a coarser cut, you simply change out the stone. I suggest you get a 60 grit stone as well as a second arbor to mount it to so you can quickly swap them out. They make stones as coarse as 24 grit if you have to remove a large amount of material.

[@chasetoncain]

okay the slowmo shot at 28:27 with the heat waves distorting the area around the billet is soooooo cooooooool i love all the fun shots put in here you guys rock

[@Mohamm3dAlObaidi]

I get the biggest dopamine rush when i see a new video from you in my feed, your content and craftsmanship is unmatched on youtube

[@nickotten1358]

By FAR the best blade smith I’ve ever seen. Just above and beyond anything else out there. Great work! You and your family make a great team! Fun to watch.

[@victorpapaavp]

36:00 The fact that you have random sharpies floating around your shop exactly where you need them is amazing! I'm glad I'm not alone in that...

[@xxitz_pr0gxx631]

I love your childlike sense of wonderment, Kyle! I can always cheer me up when I am feeling down!

[@chetton93]

Just realised the salt heater is a minion.

[@brianbain9494]

I am a self taught Blacksmith, never made Damascus. You're videos make me want to try. Beautiful work man.

[@GamesJames]

Do it! What’s the worst that happens? It fails? Meh. I wish I had the space and money for equipment. I can’t even forge at all. I hope you give it a go.

[@timbirch4999]

Do it, do it, do it!

[@kittakongoudom7393]

man I love how you have a bond with your dad. My dad migrated to US in the 80's. so all he knew was work work work to provide for family.

[@XvoseEthereal]

i think this is the most beautiful piece of metal i have ever seen in my life

[@gurraman814]

Never clicked a video so fast. Thank you!

[@DaMainMouse]

What worked for me dressing my wheels was a diamond point, first a slow pass to ensure flatness of the wheel, the last pass as fast as I could traverse would leave a sort of spiral across the stone this helps stop clogging. If your still struggling with clogging I suggest moving up to a higher friability rated stone. This will break apart faster but wont clog as often, surface grinding is always a trade between friability and heat and finish. Ultimately I made a belt conversion for hogging things down to flatish, then use a stone wheel if I need the perfect finish or sharp edges. Hope this helps 👍

[@KyleRoyerKnives]

Hey thanks my friend. Always trying to improve. Dad

[@DaMainMouse]

@@KyleRoyerKnives anytime 🤙 keep up the good work, I hope this helps in some way 🙂

[@bluebikebobowman4482]

I just watched you for the first time doing your $24,000 dagger. It is the most amazing knife I’ve ever seen you do amazing work.

[@AGRIV8TD1963]

When you take it out of the forge, heating it as evenly as possible, clamp it between two lengths of wood. A good thick strong wood, with lots if clamps. It will cool at a stable rate, usually.

[@Lazurmang]

just found your channel, and as a fellow missourian - knowing that a master craftsman/artist is somewhere round these parts makes me a bit prouder to call this place home.

[@martinsvensson179]

Next level craftsmanship, been a fan of your work for a long time, super impressed. Greetings from Sweden.

[@colinkobel2868]

Your father deserves a tremendous amount of credit! Instilling his knowledge of working metal and allowing you the freedom to use your imagination, which by the way is amazing.

[@jdesmarais187]

We use a diamond dresser welded to a plate and run the stone back and forth across the dresser works great.

[@heathbecker420]

I know this will be epic when its done but the blade blank alone is a masterwork. Kudos to you sir, your skill is unparalleled!

[@KevinMichael]

As an avid blade collector it is my dream to have a Damascus Bowie knife made by you. Your filming style music choices and ultimately the work you do is absolutely fantastic. My dad passed away recently and he was the one who got me into your channel and blade collecting as a whole. Keep forging on my dude!

[@troydruckenmiller1751]

Your salt and sand normalizer reminds me of when I worked in a foundry. I ran a giant heat treating oven. When I filled the pots with parts and sand to be treated, I used a vibrating tool to vibrate the container to remove as much oxygen as possible. It really made a difference. Something to consider.

[@troydruckenmiller1751]

I really enjoy your videos. Your knives and swords almost bring me to tears. But I am disabled on a fixed income. I will never own a custom knife. But I do enjoy watching you be a blessing to your customers. May the Lord Jesus bless you and keep you may his countenance shine upon you.

[@charleswieand4445]

Beautiful steel. Snow does not pour down that’s for rain only. Snow either floats sown gently or blows a hundred miles a hour.

[@Frosty_tha_Snowman]

It looks so wild. What an intriguing pattern. I've seen a lot of Damascus patterns, but I just can't take my eyes off of this one. It looks almost alien, or otherworldly somehow.

[@swingin871]

I was living in MO all this time with a legend and didn't even know it and now I moved to CO 😢 I would have loved to come to a knife/gun show that you attended for a meet and greet. You have such a genuine quality and positive vibes that are infectious. I'm not even a Smith and I love watching your videos and enjoy seeing how much you love your craft. May the forge be with you.

[@followingflinn8311]

You’re giving that surface grinder a workout. I think a Blanchard grinder would be a great addition to your shop. Larger area and cooler operating temps while still being aggressive

[@followingflinn8311]

Your thought of a long attachment for your belt grinder would be a much better option though.

[@ronsimpson143]

I train customer care for a large healthcare company. I sit on my couch and teach. I have a coffee mug the size of my head. I drink two of them a day. Coffee is life.

[@VinceW187]

The fact that you make absolutely amazing swords and knives, and at the same time don't take your self to seriously makes watching awesome

[@ashleystewart5156]

Dont know why i stumbled across these video,s lately, but i sure am astounded by ur craftmanship and attention to details! Perfection at its finest👌

[@thetreeshaverabies]

This is one of the best KZbin channels out there hands down. They're all so affable and talented.

[@bulvi84]

Get a diamond dressing wheel rod and drill some hex stock for that to fit in to, that will let you place it on angles to dress the sides of the wheel if you need to use the edge of the wheel for a sharp corner or anything, all you do is place the diamond slightly to the left of center and lock the bed and pass it from side to side until the wheel is no longer loaded. Love your work my friend, you have a beautiful family.

[@michaelgutierrez4845]

Super impressive as always, Kyle. Bravo

[@turantugrul7797]

You ara king of sword maker. Sword!! sword!! sword!! swoooooorrrd!!!!!! 😅😅😊

[@aidant6469]

As a Canadian who lived in the South, it always amused me just how much of a reaction something as common as snow generated with folks!

[@lukewilliams8548]

It feels weird to try to give advice to a master smith, but I'll bring up a few things in case you didn't know. Forge inserts for flux Something to take the damage of the flux instead of the forge floor, to be replaced regularly as needed. For something quick and short term, a shallow, thicker gauge sheet metal pan will help. If you know it might come up, you can buy or make a tile. "Chile forge" where I know to get them. To make them you simply cast it with forge refractory. Kast o'lite 30 is the favorite of the forum I studied (I buy it from "high temp tools"), I think I heard it's more flux resistant than satanite, but satanite is still okay. Straightening a sword hot 1. Clamp it straight while it cools. 2x4s and clamps are the most common I've seen. Doing this regularly, I've mounted a vise with 48" jaws made with steel rectangle tube and wood. 2. Having it hot and vertical Ideally you have a tall vertical oven like Kevin, but otherwise heating it in a long forge and then hanging it can work. Grinding a sword straight 1. Flat reference surface and belt grinder, contact wheels and platten. 2. At blade show "burr king" showed off their machine, a 2x72 two wheel grinder with a long magnetic chuck. They have 12, 24, and 36 inch chucks. It had a 2 axis tilting base for distal taper and hogging some material off of bevels. They said the belt grinder was 3k and the chuck was 5k. I would love it if brodbeck made a 48" surface grinder attachment, because we'd rather not spend the money and space on another belt grinder.

[@MrCarlbrooks]

Nothing quite like watching a cameraman learn what real snow does to your lighting for the first time :))

[@bryanfaulkenburg462]

I don't know about molten salt but I work in an aluminum smelter. Moisture on top of molten aluminum and the molten bath used to cover the aluminum isn't a major problem . It turns to steam instantly, it us when the molten material is on top of the moisture then it turns to steam and violently expanding 12x in volume theat the explosion happens.

[@DyamiDrumz]

A pinch of salt and one shake of dill always gives me the best surface.

[@ronbuckner8179]

Dill eh, good to know!

[@Dan_d00d]

Love your work, fun style, detail focus Kyle. With total respect and zero sass, 2 notes/ideas , from watching all your stuff a long time. 1. Read up on 'transpose' - its the term for the way you restack tiles, and anything with orientation swap/directional change, as the best used expression. (more math, less magic ) 2. Your wooden chair at the press - is it a little too high when you feed in the billets, causing a less 'level' process perhaps? Since you will sit to use the pedals. I know billet length is the issue for losing flatness anyway, but its made harder by feeding it in from above

[@tomasedson2111]

What a wonderful pattern, what magnificent work. Congratulations and all the best always.🤩🤩🤩👏👏👏

[@user-vx9od7cu5j]

My first video of you, the closest comparison for me would be an oriental rug but you did it with steel not knowing if you messed up until tons of work and effort!!! I can only hope you still get amazed each and every reveal on the grinder when what was in your head comes out to the world, thank you!!!!!

[@Quasar-fv8to]

48:00 A genuine problem I can see with this process is that, because you left the sword hanging in the air right above the molten salts, the tip of the blade will stay hotter for longer and may mess with the cooling process and grain structure.

[@MountainMythos]

Your the best on earth, if you would please consider showing off the blade at the end of the video more. In every video we barely get to see the finished product all together. I thing some high res. Photos and slow mo of the whole blade would absolutely bring your videos to the perfection that is your blade making. Thank you sir for your meticulous, flawless workmanship.

[@zmcg]

I can definitely agree you should always keep your mating surfaces clean!

[@TIAGOZONTA]

Gosto muito de ver seus vídeos, você é um verdadeiro artista meu sonho é um dia ter uma obra de arte sua.

[@xavierprunty4508]

1. Fantastic pattern weld. Looks great! Love the dedication 2. MY god the difference it make to have a powered hammer. Somewhat old school and I will not do damascus by han, I refuse to kill my body. 3. The difference money can make when setting up a shop. Using only my hands, a handfull of powered hand tools, and a hammer I make everything I can. How much did your hammer (pneumatic?) cost.

[@ben_hell4437]

I'm not sure if you have already, but can you make a playlist of this build?

[@averteddisasterbarely2339]

I left a comment but for some reason it didn't post ! Go to his playlist and all three are there !

[@chewyakarieckenicholas6049]

Mr Royer you are an artist with pattern welding steel that is one of the best patterns I've seen you do amazing work

[@Jack-dd6xd]

Okay, I don't know if you know this or not. I learned this from an old mountain man that made muskets and he told me that when you forge and heat the metal if you don't quench it facing North and South that when the metal reaches its magnetic State, just as it does, the actual magnetic pull of the earth pulls it out of straight. I've tried this and it is actually true. It doesn't affect the metal when it is non-magnetic hot, but when it cools just as it hits it's magnetic State. If you are not facing in line with the two poles of the earth, it will pull it out every time. Just a thought.

[@charleswieand4445]

Our county we had lots of companies at one time. You could quit 5 jobs and still have a job by end of the day. We got snow like that every day in 1960s , weatherman didn’t even mention snow unless it was at least a foot coming down. Worked in Bendix foundry we used ductile iron shaped stars about 1/4 thick by 3 inches around, had 2 - 36 inch wheels running with 460 volts.

[@ronsimpson143]

You should put some square tube on the backside of the press to act as an outfeed table. It will support the long blanks and help keep you from getting fatigued and help keep them from bending from its own weight. It can also help protect the stuff around it from the heat.

[@alanray3687]

Kyle, I tried out a wood workers drum sander on the blade I’m making and was amazed by how good it worked. It pulls the part through automatically and held a .005” thickness over 24”. Just had to keep flipping rotating to keep it even.

[@loganrenew4660]

Me and my buddy were watching this video and it’s beautiful, i wish you would make a billet of mosaic Damascus and sell the end pieces in small slivers so you could just see a section of the pattern, I could never afford one of your pieces but a small bit of your art would be amazing.

[@axelleaxl.5315]

In only one word? : Stunnishing ! That Pattern is absolutely beautifull, and I learn a lot on this vid with the molten salt technique.... Thank you Kyle, Thank you Mr Royer Sr.

[@jwdeepsky]

I would love to see an animation on how the Damascus pattern develops with each cut and forge

[@NeroontheGoon]

There is a single point industrial diamond stone dresser made specifically for surface grinding abrasives. The abrasive wheel is usually chucked in a fixture rotated at operating speed, and the dressing stone is moved across the work area of the abrasive. The diamond dresser produces a very repeatable and flat surface. The dresser you were using is made specifically for a bench grinder and produces a gross flat surface for a traditional grinder. That tool usually removes the clogged pores of a bench grinder wheel, making it safe to use. Ring test all your surface grinding wheels before reinstallation.

[@jo_nathan_nation6544]

Dude is such a dork, but probably the best blade smith on YT.

[@TorchPhaiz-lh1up]

I agree 100%😂😂

[@randyduane5370]

Incredible - pattern looks like floral engraving! Phenomenal!

[@Sam-yd6]

You sir are a genius. The hard work, skill and effort that it must take to get to this standard must be ridiculous. I’ve always loved your watching your videos but this sword has been on a whole other level.

[@jtbuck8558]

Unbelievable I am a beginner knife maker in one day. I hope I can be as good as you amazing work.

[@DangLinWeng83]

Kyle! Absolutely beautiful! That demascus pattern is the most eye catchingly incredible work of art. This sword will be cherished for generations.

[@Whin556]

You're one of my I fell asleep watching Forged and Fire and woke up in tomorrow land finds. You're a trip! Excellent work. I look forward to watching more of your stuff!

[@zip4real]

that pattern is awesome

[@KyleRoyerKnives]

you're awesome!

[@karimwest5083]

My PRECIOUS!!!

[@jason561120]

This is looking great. For longer heavy billets you can use a jack stand to rest the handle on, it saves on the forearms.

[@ElGoogKO]

Don't forget to go to the nations top enchanter and give it a 53k layer stack of magical effects to match the physical body. A literal legendary artifact.

[@DoctorBored357]

As a fellow Missourian, and one that loves the winter, I'm incredibly jealous of how much snow your neck of the woods got. Southeast got maybe 5 inches over the whole winter so seeing that much in just a day just doesn't feel fair. Anyway, the project is looking great so far!

[@KyleRoyerKnives]

Hey thanks neighbor. Dad

[@Chromevulcan]

You might try using a bunch of clamps to squeeze it between two pieces of thick aluminum bar so as it cools it will stay flat and true.

[@ronbuckner8179]

Kyle, I’ll bet you love your life! I’m a creative individual. I love to build just about anything. I’ve spent 46 years building businesses, and now I’m retired and if I have any regrets it’s that I didn’t spend more of my life doing exactly what you do now. Sad really.

[@etiennegirard-duchesne942]

Hey kyle, Have you ever tried clamping a sword directly on your mill table and just pass over it with a fly cutter? Would be easier, faster and probably more precise that way Great video tho and the pattern looks incredible 👍👍👍 (Also for the surface grinder you should try a diamond hone for the wheel!!)

[@efro4812]

When completed this sword will be nothing short of godly, astonishing skill @Kyle Royer

[@TF146_]

everyday kyle postes a video is a fantastic day!! been watching for years and been hooked since day one. keep on grinding brother, we LOVE IT!👍🏻👍🏻❤️❤️

[@andoletube]

10:45 When Kyle said "I'm not going to worry about it..." I said to myself, "he's definitely going to worry about it". 11:15 He didn't let me down.

[@gdogg8233]

I love this guys OCD. "I'm really not gonna worry about it too much". Next clip completely fixing the problem to perfection!

[@DrDaveSalisburyPhDMBA]

Lovin’ you dad’s sense of humor. Kevin the minion salt heater…. 😂😂😂

[@brandskovian5750]

One thing I love about this channel is that Kyle doesn’t mind telling you when and how he made a mistake. Then explains how to fix it.

[@jammin3858]

The part I'm puzzled about is when you are finishing the billet before cutting the diagonal tiles do you squish the pattern down with the press, distorting it, so when you make the diagonal cuts, weld them together and flatten and draw out the blade the pattern gets stretched back into an undistorted square area? I'm probably not describing that well.

[@WildfireDruidlvl18]

The forge is strong with this one

[@ericneilson9151]

You're getting better all the time! I like seeing you interact with your family. Excellent video.

[@moondoggie1987]

That pattern looks great even if you didn't do the bath of coffee it looked great just with the granite look to it.

[@cra10crawler]

Usually you should use a diamond in closed into a block of steel, set it on the magnet and move the stone cross it to get it parallel to the magnet. Love your work.

[@KyleRoyerKnives]

We do when doing finish grinding but not for rough in. Keep grinding on my friend. Dad

[@RagingZoner]

Great video as always! Just wanted to see the finished sword!

[@sorayaya3080]

After the normalizing process, I always let out a sigh of relief Because a huge damascus sword forged into shape like that must be under so much stress that I'd bet dropping it on the ground by accident could just crack it

[@WhatChaThink01]

Kyle we do get a lot of snow and the weather is quite crap the last couple years have been weird il give you that. I know that shop is warm, but step out more often lol

[@alf9638]

That pattern is ridiculous............woah

[@jamescapps4553]

Wow...wow....wow!!!!! Amazing pattern. Can't wait to see the finished sword.

[@gameface8080]

Can you etch the billet before you cut the tiles on the next build. Just to show an example of what the straight lines look like.

[@GuillotineStare]

That forge blade looking about as straight as you my man! lol! Love the videos!! Thanks!

[@tonycabrini5488]

You guys made my Friday in CA by posting this video. Tnx again god bless you and your family

[@KyleRoyerKnives]

Hey thanks my brother. May God bless you and your crew as well. Dad

[@herbilishes]

I really like the long videos, and obviously ur families skills will everything that goes into the making of blades and videos

[@IAMMRPATRICKBORNAGAIN]

This might sound like a silly question, but have you ever done a flex test on a finished mosaic Damascus blade? Not a customer piece obviously, just a scrap one. Thanks.

[@trevortrevor6495]

Firstly, wow! Sick pattern! Secondly it's cool that you get an even leg workout on that press.

[@creightonleerose582]

-Might a copper/thin sheet steel 'Torus' type 'donut' catchment system attached to ceiling catch any eruptions of molten salt IF any moisture were to cause a vertical explosion plume? The inlet/outlet radius of the salt bath vessel is what?...About 5 inches in diameter? (Kinda hard to tell by vid) -Think like a circular innertube with the inside of the 'Donut hole' radius cut 3/4 way up its inside arc to help contain any splash from ceiling & the inside arc of the 'donut' to catch splash, its exterior then follow all the way to affix to ceiling? -The circular 'J' or backwards/> -Like an backwards/left facing capitol G, but its foot angled facing the 1 or 2 o clock position, any splash would re-direct it back towards the curved donuts outside wall, reduce its momentum, then pool it @ its bottom curve... -That lip might retain any spill from splashing out over the top of inside torus? -Just a thought, I'd be MUCH better off drawing it for yee's, then try'n 'ta explain it!...HA!... -Im CERTAIN the two of ya's can visualize what Im speaking of?... -You can never be too safe when working with that sort of stuff......ONE 'oopsie' is all it takes....;)

[@Max_Griswald]

Awesome pattern!

[@TRichardsBlades]

I've used 2 pieces of angle iron and clamped my blades between them to get them straight and keep them straight while they cool, dunno if it would work on such a large blade, but i've done up to a 21 in wakizashi in that method and its worked great