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 who needed to put food on the table and protect his home and family. But the rifle's of no use against the tiny invaders who've moved into Daniel's dad's home, so he brings in the big guns to remove a colony of honeybees to a hive of their own. Then at a family dinner, the buzz is all about Daniel's news of a new addition to the Casey clan.

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. So Daniel salvages steel and wood from days gone by to hammer out his own version of the 200-year old antique. He takes time out from the painstaking task to repair a Civil War-era rifle -- and blow off some steam with friends shooting targets with black powder flintlocks.

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. Will Daniel's reputation remain on track, or will the rifle miss the mark?

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 when it comes to strength and beauty. Also, with a new baby on the way, Daniel needs to build an addition to his house.

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, earning its' nickname the "fowler." Daniel also needs to figure out a way to move his shooting range farther from his house.

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 musketball stuck inside the barrel of a rifle. Working on a loaded gun with a .50 caliber round jammed inside means the slightest miscalculation can cost him a limb... or even his life.

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, and his mentor watching over his shoulder, the pressure is on for Daniel.

As winter settles into the Ozarks, Daniel is hard at work forging an Early American-style grease lamp. At the same time, Daniel's tackling a rare 1842 rifle commissioned by the US government for trade with the Indians. Meanwhile, Daniel's called in to help clear a massive beaver dam that's causing trouble on a friend's land.

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 to create what Bob likes to call "Flint Lock Art."Source: History Channel

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, Daniel wants it to be waiting for him when he is ready, so he sets out to build a miniature sized poor boy rifle.