2. Planning Your DIY Still: Essential Considerations

When venturing into the world of home distilling and moonshine still building, one of the first lessons I learned was the importance of matching my DIY skills to the still design I chose. It's a bit like cooking; you wouldn't start your culinary journey with a soufflé, would you? The same goes for building a still. Your experience, patience, and willingness to learn all play a big part in deciding whether to start simple with a pot still or to tackle the more complex reflux stills.

Choosing the right still design isn't just about ambition; it's about practicality. A pot still, with its straightforward design, is perfect for beginners and those looking to create spirits rich in flavour. On the other hand, a reflux still, though more complex to build and operate, offers a cleaner, higher-proof spirit, appealing to those with a bit more experience or seeking a challenge.

Now, before you start dreaming up your first batch of moonshine, here's a 10-point planning checklist to help prepare you for the journey ahead. This checklist is your roadmap to ensure you’ve considered all the necessary details before diving in:

1. Determine Your Skill Level: Be honest about your DIY capabilities.
2. Research Still Designs: Understand the differences and requirements.
3. Space Availability: Ensure you have a safe, adequate space for distilling.
4. Budget: Calculate the cost of materials, tools, and potential upgrades.
5. Legal Considerations: Check your local laws regarding home distillation.
6. Safety Measures: Plan for ventilation, fire safety, and emergency procedures.
7. Time Commitment: Estimate the time needed for building and distillation.
8. Resource Accessibility: Ensure you can obtain all necessary materials and tools.
9. End Product: Decide what spirits you aim to produce.
10. Learning Resources: Identify books, websites, and communities for support.

Making the right choice in still design is crucial for achieving the results you desire. Whether you're drawn to the rich, flavourful spirits produced by a pot still or the clean, high-proof spirits from a reflux still, understanding their differences and uses is key to your success as a distiller.

4. Gathering Your Materials and Tools

When embarking on the journey of DIY still build, selecting the right materials is as crucial as the plans themselves. While copper often takes centre stage due to its excellent heat conductivity and beneficial chemical interactions during distillation, it's just one piece of the puzzle. The materials you choose, from the body of the still to the smallest fitting, all play pivotal roles in the quality and safety of your final product.

Beyond copper, which should be sourced with a clear history to avoid any contamination risks, there are several other components to consider. Stainless steel, often used for the boiler, offers durability and resistance to corrosion, making it a reliable choice for long-term use. However, ensure that the stainless steel you select is food grade to avoid leaching unwanted chemicals into your distillate.

When building a DIY Still its often tempting to use something you already have on hand, especially when it comes to fittings. As tempting as it may seem, you first need to know what material the fittings are made from. The most common type of fittings found in sheds, that are used on DIY stills, are common household plumbing fittings. These fittings contain lead which can leach out when in contact with the high ABV alcohol generated in the still. The result is that the lead ends up in your finished product, leading to lead poisoning. Brass fittings should be avoided at all costs.

Sealants and soldering materials demand equal attention. Opt for high-temperature, PTFE options when it comes to gaskets. 100% silicone with no fillers can also be used for gaskets as well. As for solder, it must be lead free, end of story!

Thermometers and pressure gauges are your window into the distillation process, allowing you to make precise adjustments for optimal results. Accuracy here is non-negotiable, as even slight deviations in temperature can lead to significant differences in the quality of your distillate.

Cooling systems, vital for condensing vapor back into liquid, should be efficient and clean. Whether you're using a simple coil or a more sophisticated setup, regular maintenance and cleaning are key to preventing blockages and ensuring the purity of your product.

Lastly, sourcing your materials from reputable suppliers cannot be overstressed. Whether it's the copper for your column or the nuts and bolts holding everything together, knowing the origin and intended use of each component ensures that your DIY still is safe and effective for producing high-quality spirits.

1. Copper Tubing/Piping (vetted for a clean past, of course)
2. Stainless Steel Boiler Material
3. High-Temperature Sealants
4. Reliable Thermometer and Pressure Gauge
5. Condenser Components for Cooling
6. Soldering Gear (suitable for food-grade work)
7. The Right Tools (think drills, cutters – the good stuff)
8. Safety Gear (never skimp on this)
9. Pristine Cleaning Supplies
10. Plans You Trust (like those I've got on my site)

5. Overview of Building Your Own Still

Tackling a still build from scratch is really like putting a jigsaw puzzle together. Each piece has its place, and if you want the whole thing to work, you’ve got to get each part right. That’s where having solid, detailed plans to follow comes into play. On our site, we have a set of very detailed plans on how to build a still using an old beer keg as the boiler and some readily available copper pieces for the head and condenser. It’s a basic pot still but in my opinion is the best moonshine still for beginners, and a great DIY build to develop your skills as a still builder. You can read more about these moonshine still plans in PDF format HERE

When you start assembling your still, it’s all about following each step carefully, making sure you don’t skip anything. Our plans are laid out to help you through the entire process, making it straight forward. They’re born from a heap of experience in distilling, simplified into something you can easily follow at home.

Why do you really need detailed plans? Well, for starters, they keep you on track. Avoiding mistakes means you won’t have to backtrack or redo any work. Plus, getting it right from the start saves you time, money and hassles. But the biggest deal is safety. When you’re working with heat and potentially flammable materials, there’s no room for error. Everything needs to be spot on for your DIY still to be safe and efficient.

So, as you gear up to build your still, think of these plans not as a sales pitch but as a helping hand. They’re here to help you make a still that’s up to scratch, capable of producing quality spirits safely. With a good set of plans, building a still becomes less about guesswork and more about the enjoyment of crafting something that works well, right from the first run.

6. Operating Your Homemade Still Safely

Once you've got your still set up and ready to go, operating it safely is the next big step. This isn't just about getting a good batch of spirit; it's about doing it without any hiccups or hazards. Distilling at home can be incredibly rewarding, but it's essential to respect the process and what it involves — mainly, dealing with heat, potentially flammable vapours, and pressure.

First off, always monitor your still during operation. Distilling isn't a set-and-forget kind of task, never leave your still whilst it’s running! You need to keep an eye on the temperature and pressure to ensure everything is running smoothly. This vigilance helps prevent any unwanted surprises, like pressure build-ups or temperatures veering off course.

Ventilation is another critical factor. Make sure you're distilling in a well-ventilated area to avoid the build-up of any vapours. These vapours aren't just a fire risk, they can be harmful if inhaled in large quantities. An outdoor setup is ideal, but if you're inside, ensure windows are open, or better yet, use an exhaust fan to keep the air moving.

Fire safety is paramount. Since you're dealing with heat and flammable materials, having a fire extinguisher nearby is a must. Also, make sure your still is set up on a non-flammable surface. It's all about minimising risks so you can focus on the craft of distilling without worry.

Lastly, regular maintenance is crucial. Keeping your still clean and in good working order not only ensures safety but also the quality of your spirit. After each run, take the time to clean your equipment thoroughly, checking for any wear and tear that might need addressing.

Remember, distilling at home is as much about enjoying the process as it is about the end product. By operating your still safely, you ensure that this hobby remains a pleasure, allowing you to experiment and refine the craft of home distilling over time.

7. Your First Distillation: Getting Started

Now that you've got your moonshine still all set up and you're clued up on safety, it's time to talk about running your first distillation. This is where the rubber meets the road, or more accurately, where the mash meets the heat. It's an exciting step, but also one where patience and attention to detail really pay off.

Before you start, make sure you've got your recipe dialled in. Whether you're working with a tried-and-true classic or experimenting with something a bit more adventurous, knowing your ingredients and their proportions is key. It's a bit like cooking; the better your prep, the better the outcome.

As you begin to heat your mash, keep a close eye on the temperature. You're looking for that sweet spot where the alcohol starts to vaporise but the water doesn't. It's all about control here — too hot and you'll end up with too much water in your distillate; too cool and you won't get much of anything.

Remember, the first bit of liquid you collect, the "foreshots," isn't something you'll want to keep. It contains compounds like methanol, which you definitely don't want in your final product. Discard this part. After the foreshots, you'll start collecting the "heads," followed by the "hearts," which is the good stuff, and finally, the "tails," which can be reused or discarded based on your preference.

Throughout this process, your senses are your best tools. Smell and taste (carefully) to gauge the quality of what you're collecting. It's an art as much as it is a science, learning to recognise the subtle shifts that indicate what part of the run you're in.

Your first distillation might feel a bit like a balancing act, but don't worry. Each run is a learning opportunity, and before long, you'll start to feel like a seasoned distiller, able to navigate the process with confidence. So, take your time, enjoy the journey.

8. Cleaning and Maintenance: Ensuring Longevity

Moving onto the next chapter in our distilling saga, let's tackle cleaning and maintenance—because keeping your still in tip-top shape is just as crucial as knowing how to use it. After all, a clean still is the key to producing quality spirits, and let’s not forget, it’s also about safety.

After every distillation run, giving your still a thorough clean is non-negotiable. You don’t want any residue or build-up of organic matter affecting your next batch's flavour or, worse, causing safety issues down the track. Start with disassembling your still as much as possible, you know how to do this because you built it. It might seem like a bit of work, but it's the only way to ensure every nook and cranny gets the attention it deserves.

For the cleaning itself, warm water and a mild detergent are your best friends for most parts. However, for those copper components, consider using a vinegar solution or a specialised copper cleaner to keep them shining and functional. Copper's great for distillation, thanks to its natural antimicrobial properties and ability to remove sulphides, but it does require a bit of extra love to maintain these benefits.

Once everything's washed, give it a good rinse with plenty of clean water. Any detergent or cleaning solution left behind can mess with your spirit's flavour, and we don’t want that. After rinsing, make sure everything is bone dry before you reassemble and store your still. Moisture is the enemy of metal, leading to corrosion and wear over time.

Regular maintenance checks are also a great idea. Keep an eye out for any signs of wear and tear, especially on seals and connections. A small leak or a worn seal can not only affect your distillation efficiency but can also be a safety hazard.

Remember, the effort you put into cleaning and maintenance of your still pays off in the longevity of it and the quality of your spirits. So, take the time, do it right, and your still will serve you well for many runs to come.

9. Expanding Your Distilling Skills

Alright, let’s talk about expanding your distilling skills. Once you’ve got the basics down and you’ve run a few batches through your still, it’s natural to start thinking about what’s next. Distilling, like any good craft, is a journey—not a destination. There’s always something new to learn, a different technique to try, or a unique recipe to concoct.

First things first, experimentation is key. Don’t be afraid to try new things. Whether it’s tweaking your mash recipe, adjusting the cut points during distillation, or infusing the final product with herbs or fruits, these experiments can lead to some fantastic spirits. Just remember to keep detailed notes on what you try. This way, you can replicate your successes and learn from anything that doesn’t turn out as planned.

Next, consider deepening your understanding of the science behind distillation. Knowing the ins and outs of what happens during each phase of the process can help you refine your technique and improve your spirits. There are plenty of resources out there, from books to online courses, that can take your knowledge to the next level.

Another way to expand your skills is by connecting with the distilling community. Whether it’s online forums, social media groups, or local clubs, there’s a wealth of knowledge and experience out there. These communities are great for sharing tips, asking questions, and even swapping spirits for feedback.

Lastly, don’t forget about the presentation. Learning more about bottling, labeling, and presenting your spirits can turn a good homemade spirit into a great one. It adds to the overall experience and can make your spirits stand out if you decide to share them with friends or family. Start by creating personalised label for your spirit. It’s a great way to give your bottles a professional look, and at the same time, the opportunity to tell everyone what’s in your product.

For those wanting to create their own label there are a number of online label creators for beer labels that can easily be adapted to spirits. One I have used with success is Beer Labelizer. 

If you’re wanting more control over the creative process then there is an awesome guide on YouTube which runs you through the entire process from start to finish. You can find that guide here. If you’re not tech savvy and want someone to do the design work for you then a great option is Etsy.

Expanding your distilling skills is all about curiosity, patience, and a willingness to learn. So, keep pushing the boundaries, keep refining your craft, and most importantly, keep enjoying the process. After all, the best spirit is one that’s enjoyed both in the making and in the tasting.

10. Troubleshooting Common Issues

Diving into troubleshooting common issues, it’s a bit like being a detective in your own distillery. No matter how meticulous you are, you’re bound to run into a hiccup or two along the way. The key is not to get discouraged. Most problems you encounter have solutions that are simpler than you might think.

One common issue is a low yield from your runs. If you find yourself getting less out than you expected, double-check your starting alcohol content of your mash. Sometimes, the issue is as straightforward as the fermentation not fully completing. A stuck fermentation can often be kick-started again with a bit of warmth or additional yeast.

Another hiccup you might face is off-flavours in your final product. This can stem from several sources, like fermentation temperatures being too high or not making clean cuts between the heads, hearts, and tails during distillation. Paying close attention to your process and temperatures can help mitigate this issue. Also, ensuring you discard the foreshots and making precise cuts will help keep those unwanted flavours at bay.

Leaks in your still setup can also be a common problem. They’re not just a nuisance; they can be downright dangerous. Regularly inspect your still before use, checking for any signs of wear and tear or loose fittings. A simple tightening of connections or replacing a worn seal can often fix leaks.

Lastly, if you notice a decrease in the efficiency of your still over time, it could be due to scaling or build-up inside your equipment. Regular cleaning and maintenance, as we’ve discussed, are crucial to preventing this.

Remember, troubleshooting is all about observing, diagnosing, and adjusting. Keep detailed notes of what you do, what works, and what doesn’t. This way, you become more able to spot potential issues before they become real problems, keeping your distilling smooth, safe and enjoyable.

11. Legal Considerations and Ethical Practices

Tackling the legal considerations and ethical practices of home distilling is a topic that's as important as any part of the distilling process itself. It's the groundwork that ensures everything we do in our pursuit of crafting the perfect spirit stays within the bounds of the law and respects the craft itself.

First off, it's crucial to familiarise yourself with the local laws and regulations surrounding distillation. Depending on where you are in the world, the legal landscape can vary significantly. In some places, distilling alcohol for personal use requires permits or might be restricted altogether. The key here is to do your homework. Understanding these regulations not only keeps you on the right side of the law but also helps promote a responsible and respectful distilling community.

Ethical practices in distilling go beyond just adhering to legal requirements. It's about respecting the craft and those who enjoy it. This means being mindful of the quality and safety of the spirits you produce, ensuring that anything you share with friends or family is something you're proud of and confident is safe to consume. It also means being honest about what you've created, sharing your methods and ingredients openly.

Sustainability is another aspect of ethical distilling. Where possible, sourcing ingredients locally, minimising waste, and considering the environmental impact of your distilling practices can all contribute to a more sustainable approach to this age-old craft.

In essence, navigating the legal and ethical considerations of distilling isn't just a responsibility; it's an integral part of the craft that enhances the experience for everyone involved. By staying informed, respectful, and conscientious, we can ensure that home distilling remains a rewarding pursuit for generations to come.

12. Conclusion: Embracing the Distilling Journey

Wrapping up our deep dive into the world of home distilling, it's clear that this journey is as rewarding as it is complex. From choosing the right materials and assembling your DIY still to mastering the art of distillation and navigating the legal landscape, each step brings its own set of challenges and triumphs. But more than anything, it's a journey of discovery, creativity, and community.

Home distilling is more than just a hobby or a way to make your own spirits, it’s carrying on a tradition that stretches back centuries. It connects us with the past, with the pioneers who distilled spirits out of necessity, innovation, and artistry. Yet, it also roots us in the present, in a community of like-minded people who share tips, triumphs, and the occasional flop.

As you continue to refine your skills and deepen your understanding of distillation, remember that every batch is a learning opportunity. Whether you’re perfecting a family recipe or experimenting with new ingredients, the essence of home distilling is exploration. There will be moments of frustration, no doubt, but also moments of sheer delight when you taste a spirit that is uniquely yours.

Looking ahead, the possibilities are as endless as your curiosity. Maybe you'll explore aging spirits to add depth and character, or perhaps you'll dive into the chemistry of flavours to create something truly innovative. Whatever path you choose, know that the journey of distillation is one of continual growth and endless fascination.

Cheers to the journey ahead, filled with discovery, craftsmanship, and the joy of sharing a good drink with good friends.

Dave