【Key characters】

Hideki Sugiguchi : CEO of Motion Actor Co, Ltd.

「SUG-AFTRA stunt performer」。He is a leading figure in the Japanese XMA world.
He is a 20-year veteran of motion actors.
With his amazing physical abilities, he has appeared in many domestic and international productions including Hollywood. Please check the link below for the works!


【Twitter (@jagar001)】

Akihira Kawasaki:Master of Japanese sword

He is reputed as one of the swordsmiths who has reached the highest level among the swordsmiths who pass on the Soshuden (one of the Five Legends of Sword Propagation).

【Akihira Tantou Dojo】 


Hideki Sugiguchi, who continues to be at the forefront of the industry as a motion actor and suit actor, asked Akihira Kawasaki, a Master of Japanese sword who has a sword dojo in Saitama Prefecture, to make a own Japanese sword... ! Akihira are said to have attained the highest level among swordsmith who have passed down Soshuden (one of the five legends of the propagation of swords) today. The master craftsman kindly agreed to release the swordmaking process, and the production of this video series started!
This video series is an unprecedented documentary about Sugiguchi's request to Akihira to produce a Japanese sword, and the process by which a block of iron is reborn into a beautifully sharpened Japanese sword, as well as Sugiguchi's performance using the finished sword.

This series, in which Japanese Sword master Akihira Kawasaki makes a Japanese sword for Hideki Sugiguchi, CEO of Motion Actor Co., Ltd., has already reached its sixth edition.
In the previous issue, we finished the Agegitae process and progressed to the Forge welding of the Shingane (芯鉄:core iron) and Hahagane (刃鋼:blade steel).
This time, we will introduce the "Tsukurikomi(造り込み)'' process, in which skin iron (皮鉄:Kawagane) is forged on both sides of the iron, and the "Aranobashi(荒延ばし)'' process, in which the forged iron is lengthened.

【Point note】

Akihira explains the process.
Sugiguchi's Japanese swords are made with a structure called "Hon-san-mai(本三枚)". This is the part of the production process that Akihira doesn't want to make public.
Both Sugiguchi and the camera crew took great care not to disturb the swordsmith's concentration.

The skin iron forged in the Agegitae process was divided into two.
The lengths of the two skin irons are slightly different. 
First, by forge welding a short skin iron to the core iron, and then Forge welding a long skin iron to the core iron, the overall length of the iron becomes slightly longer.
In anticipation of this, another iron skin is made longer.
After forge welding the core iron and the skin iron, the iron proceeds to the "Aranobashi" process, which lengthens the iron.

Blade steel is made of the same material as skin iron. But it  Orikaeshi-Tanren(folding and forging) about 1 to 2 times more than skin iron.
As far as Akihira calculates, the amount of carbon is reduced by about 0.03% in one Orikaeshi-Tanren.
The blade steel with reduced carbon content is hardened to increase its hardness.

The first iron is aligned with the core iron (and blade steel attached). If you look closely, you will see that the core iron and the skin iron are almost exactly the same size. Japanese sword master can predict this without even using a measuring tape.

Beginning of Tsukurikomi(造り込み).
Once the two pieces are stacked on top of each other, they are heated to a high temperature in the hodo. When the iron is sufficiently red, it is removed from the hodo, covered with straw ash and mud, placed in the hodo, heated, and Forge welding.
Notice the movement of Sakite as he wields the large hammer. Do you notice the difference from the previous sounds, sparks and movements?

Here comes the Fusahiro Shimojima Japanese sword master. You are already familiar with this video series. Thank you for everything.

Isn't it lovely how you use the hand hammer like a hand to carefully stack and align the irons?
The second skin iron was made a little longer, but it is exactly the same length as the core iron at this stage.
Akihira had anticipated this.

The second skin iron is matched to the core iron. At first, they are just piled on top of each other and heated at a high temperature.
When the iron is hot enough and red enough, borax is placed between the irons, covered with straw ash and mud, heated in a hodo, and Forge welding.
The sound of the large hammer wielded by Sakite is subdued at first. The reason for this is to carefully Forge welding.
Gradually, the hammering becomes more powerful.

You noticed the change in the shape of the iron, didn't you?

Sugiguchi, you are up.

Will Fusahiro join the photo crew?

The best combination of Yokoza (横座) and Sakite (先手) is the prerequisite for a great job.

The beginning of Aranobashi(荒延ばし).
Just by striking the iron, it will stretch longer and longer into a bar shape.
Please enjoy the drastic shape changes of the iron from here to the last.

Akihira picked up the charcoal that rolled out of the Hodo with his fingers and returned it to the Hodo. Maybe his fingers don't feel the heat of the charcoal?

The iron becomes even longer and flatter.

Okay, ・・・・・・・・ complete," Akihira said.
All the participants applaud in unison for the powerful and enthusiastic creation!