Iron & Fire

In the heart of the Ozarks, traditional knife and gunsmith Daniel Casey breathes new life into a 200-year old classic as he crafts a custom "Poor Boy" rifle. This was the weapon of choice for the average man of the 1800s.

As ironsmith Daniel Casey begins to craft a replica of the very first Bowie knife ever made, he has a big pair of boots to fill. After all, Arkansas is where that American original was first forged in the early 19th century - and it's become a classic.

Daniel has been given a new challenge: create an 18th century North Carolina style rifle for a professional shooter. Due to the need for extreme accuracy. Daniel will test the gun by splitting a ball on an axe head.

Daniel has been given the task to replicate a Damascus steel blade dagger using forging techniques that haven't changed for centuries. Favored by Samurais, Vikings, and other legendary warriors, Damascus is considered to be the superior steel.

Daniel crafts a custom "smooth bore" shotgun, made with locally harvested walnut. This short-range weapon was the gun of choice for soldiers in the Revolutionary, French and Indian wars - then over time it became widely used for hunting birds.

Daniel tackles an iconic and challenging Native tool: The Pipe Tomahawk. Meanwhile, Daniel's worried about flooding on his property and cooks up an explosive plan to deal with a log jam.

Daniel sets out to build a cannon from salvaged materials and it's going to have some fearsome firepower. But first, Daniel has to help a friend with one of the most dangerous jobs a gunsmith ever attempts: removing a stuck musketball.

Daniel works on an 1850's percussion rifle for a very particular client. While working on the restoration, Daniel and the guys find time for a friendly fish gigging competition.

Daniel travels to Kentucky to work with his mentor on a powerful Bear Pistol. Normally taking four weeks to build, Daniel only has four days to get this build together. With time against him the pressure is on for Daniel.

Daniel tackles a vital project for any traditional blacksmith: crafting his own tools. Meanwhile, his buddy needs to clear a massive beaver dam that's causing his cow pastures to flood. The guys hatch a big plan that involves precision shooting.

The Casey boys are invited on a traditional hog hunt, and Daniel forges the ultimate spear for the occasion. Meanwhile, Daniel gets some quality time with his three-year-old son, Wesley, and Bob and the boys head to the firing range.

After restoring and building countless guns and knives for his customers, master blacksmith Daniel Casey decides that it's time to build a rifle for a very special client: his son Wesley. Although Wesley won't be old enough to shoot it for a few years.