if i were gonna make my own fuel......diesel. easy, cheap, and somewhat safe.
Ethanol production from the safety aspect isn't all that bad. Ventilation, good soldering, and an uninterrupted supply of cooling water largely keep you in one piece.
Now, if you watched that show moonshiners, keep all Tickles far away.
For us Farmer folks, me being one of them, if your setup right, you can recoup some of the cost of production simply from the waste. In fact, Distillers and Brewers grains are chemically rearranged to make a much better quality feedstock. Corn out here in Wa a month ago was $308.00/ton. which equals 37 bushel. Thats already ground fine enough to mash, saving a step. Each bushel should produce appx 3.5-4.0 gallons of 190.
So, just in grain you already have $2.00/ gallon into it. A good still that can produce 1/1.5 gal hr will run you about 1500-2000 in parts and automation to a degree. So to recoup the still cost at 4.00 gas, you need to make at least 1000 gallons or in terms of bushels 150 bushels of corn. That is about the equivelent of 5 pickup loads of corn.
No you add in your time. it takes me about 3 hours to prep a 30 mash gallon run from complete scratch then 12 hours to distill it to 150 proof (2x through). If I count my time in labor at even say minimum wage, I have another $125 into that 5 gallons. So my gallon of gas, is technically costing my close to $29.00 a gallon.
If you don't count your time, which I really don't anymore because I have largely automated the process, and if I feed the grain to my cattle saving that cost, I knock that price way down, somewhere in the range of 5.00 a gallon.
When I go to my next version this fall, and if I start growing my own barley, I figure I can get my cost down to $4.00 a gal, but, even then it will be for my 2 tractors that still run gas, and my lawnmowers.
In the end I have fun doing it. I only do it in the winter because I have time, I dont drink it because well.... my wife doesn't like me afterwards, I use recovered rainwater for cooling because rains endlessly here from nov-apr, and I love trying to increase the efficientcy.
Get your permit, and don't let your buddies talk you into buying it.