Send us Fan Mail We sit down with the founders of KO Distilling to trace how a Ravens game conversation turned into a Virginia craft distillery with serious bourbon and cask strength rye. We get candid about equipment upgrades, control-state distribution, barrel strategy, and why barrel picks with a cigar club can become a real community engine. • the origin story from Merchant Marine Academy to a third career in distilling • learning licensing, regulation, and taxes while building a distillery from scratch • hiring a head distiller with chemical engineering and distilling science training • how military and engineering habits show up in process, safety, and consistency • the shift from pot still whiskey to a continuous column still and what it changed • building a tasting room experience inside an industrial warehouse space • naming the brand, winning trademarks, and why Bare Knuckle fits KO • developing rye from early young releases to older cask strength expressions • blending for consistency, setting aside unicorn barrels for single barrels • barrel sourcing with Kelvin Cooperage and navigating shortages • cracking Virginia ABC distribution and pitching for shelf space • online sales via retailers and why hazmat bourbon sells fast • cigar club barrel picks, pairing notes, and the hands-on bottling and labeling day www.scotchyburbonboys.com for all things, Scotchy Bourbon Boys. Check out our t-shirts, our Glen Karens, and then also follow us on Facebook, YouTube, Instagram, and X along with Apple iHeart and Spotify. Leave good feedback, become a member A craft distillery doesn’t get built on vibes, it gets built on hard lessons, tight process, and a lot of unglamorous decisions. We’re joined by the team behind KO Distilling in Manassas, Virginia, the makers of the Bare Knuckle line, to unpack how two longtime friends and Merchant Marine Academy grads turned a “what if we started a distillery?” moment into real whiskey on real shelves. We talk about the early reality most people never see: licensing, control-state rules, taxes, and the constant need to learn fast without cutting corners. They explain why their engineering and military backgrounds actually matter in a distilling operation, from pumps and valves to boilers, safety, and repeatability. Then we get nerdy about the production side, including the jump from pot still distilling to a Vendome continuous column still, and how they kept their bourbon and rye profile consistent while scaling. From there, we dig into what whiskey fans are chasing right now: cask strength rye, single barrels, and the “unicorn barrel” you just can’t blend away. We also cover barrel sourcing with Kelvin Cooperage, the economics of distribution through Virginia ABC, online ordering across multiple states, and a limited hazmat bourbon release that disappeared fast. Finally, we bring in a cigar club that does KO barrel picks to share what bottling day is like when fans help label, proof, and take the bottles home. If you enjoy craft bourbon, Virginia rye whiskey, and behind-the-scenes distillery stories, subscribe, share this with a whiskey friend, and leave us a review. What bottle would you want to pick from a barrel? If You Have Gohsts Support the show https://www.scotchybourbonboys.com The Scotchy bourbon Boys are #3 in Feedspots Top 60 whiskey podcasts in the world https://podcast.feedspot.com/whiskey_podcasts/