One thing not common knowledge, and rarely mentioned, is that ALL participants are required to sign a non-disclosure agreement. It is very strict and they can't discuss the filming, details about how it is put together, what the participants are paid, any scripting, created shots, or other parts of how things are done and the order they are done in. The penalties are severe if they do. They are given a set or rules of what they are to say and not say.
I have talked to several of the contestants in person, as well as on the forums. I know others from Ashokan and other get-togethers, and have seen them work, and the knives they can produce. When asked about the show, they universally say it is hot, noisy, very bright, and a whirlwind. They also all say they can't talk about any more than that. In more private talks, there is an implication that some things seen are for effect. They also say that the order seen in grinding and forging isn't exactly in chronological order. Most say they are told the quenchant is a commercial quenchant and nothing more. When asked if there is something else added to make the flames, they say "I don't know". When asked about the tempering, they say very little except that "it is done overnight by someone else, and they have no control over it."
My personal observations where there are things that don't add up are:
Dropped steel/blades that catch the floor on fire.
Flaring quenches
And my biggest question is them quenching a blade and going immediately to the grinder and grinding for 30-40 minutes on a fully hardened and un-tempered blade. You even see some sighting down the blade and trying to straighten a warp ... on a un-tempered blade. I believe some of these shots are from day 2 and are inserted into the scenes from day 1 to make more excitement.
I think most of the mistakes are real. We all make them, and under the rush and chaos of the filming, they get easier to happen. I do have doubts about most of the drama shots.
Besides the "doomed to fail" materials choices at times, I think that the producers deliberately put other pitfalls in the show with things like unsuitable handle materials and resins that can not be used in just an hour. Having them on the shelves sets a trap for people to make a mistake.
Some things defy logic. Using two hardeners/resins, with the camera right there in a close up of the shelf as you take them off. And the judges seeing it from across a busy ( and often smoky) set.
It is also somewhat unlikely that every single contestant leaves saying ,"I did my best, my knife/sword/blade failed to meet the tests, I'm OK with getting kicked off." We all know some of those chaps are known to be a bit argumentative and vocal in their opinions. It is far more likely some would say, "Screw you, that was the worst cut with a sword I ever saw. It wasn't my sword that failed, it was Doug's stupid sideways cut!" The fact that not one contestant ever discusses the obvious problems with the testing and other issues is also telling.
Last comment - We all need to remember that there are many scenes shot after the timed period is over ... when he events of the day are known to everyone. Scenes like the aside comments from the contestants are shot long after the event they are talking about ( usually wearing different clothes), and the judges group shots of,"Oh, no, not the water!" and other comments about procedures and materials are normally shot later on and inserted. It may take four or five tries to get it to look natural. I have a few friends who are privy to the production of other History channel and food network competitions and they all say that these scenes are often shot after the whole competition is over to make fill time for airing in a certain time frame. They also say that many of the scenes are directed, some are shot with a basic guidance command (drop the steak on the floor and say, "Oh no, I have to come up with another plan!"), and some are scripted. FIF is probably as it happened for the main part, with extra drama and fire added to make it appeal to the mass audience.
Here are extensive past threads with some of the contestants comments:
http://www.bladeforums.com/forums/s...orged-in-Fire-contestants-introduction-thread
http://www.bladeforums.com/forums/showthread.php/1300844-Forged-In-Fire
http://www.bladeforums.com/forums/showthread.php/1300940-Thoughts-on-Forged-in-fire
http://www.bladeforums.com/forums/showthread.php/1374949-Forged-in-Fire-Am-I-mising-something