6) the relay, or dry barrel
7) the long thump rod—its connection with (15) is hidden
8) top half of trough from heater
9) bottom half of trough
10) handle for heater box gate
11) heater box
12) copper connecting rod
13) flake stand—water filled
14) outlet from condensing unit
15) thumper, or thump barrel
16) bucket for slop, or “pot-tail”
17) slop trough
18) slop arm from still
19) handle of plug stick
ILLUSTRATION 14 The beer in this cooker is being heated prior to sealing on the cap. The swab stick resting in the cooker is used to stir the beer while it is heating to keep it from sticking to the sides and burning. Both this and the next three photographs were all taken at the same operation.
ILLUSTRATION 15 The thump barrel and heater box. The drain pipe, when lowered, carries warm, fresh beer from the heater box to the cooker, the top of which is visible in the foreground.
ILLUSTRATION 16 The heater box from the other side, showing the connection between the heater box and the condenser which is mounted in the metal drum.
ILLUSTRATION 17 The whole operation from the heater box, condenser end. The wooden barrels on the right are rilled with fermenting mash. The furnace is hidden behind the heater box. The plastic gallon milk jar in the foreground is often used in place of glass jars for the finished product.
ILLUSTRATION 18 This page reveals a heater box and a thump barrel in more detail. The barrel in the foreground of the photograph is the thumper. The pipe extending in the foreground is the long thump rod coming from the cap of the still. (This particular still did not have a dry or relay barrel). The large wooden box behind the thumper is the heater box. Arrow 1 points to the outlet which is blocked by the gate behind it. Arrow 2 points to the handle of this gate. Arrow 3 points to the wooden trough which is mounted into place when the operator is ready to transfer his preheated beer to the still for a new run. In the background, behind the thump barrel (bearing the number 4) can be seen the corner of the flake stand.
ILLUSTRATION 19 (1) is the cap—usually a fifty-gallon barrel. (2) is a huge barrel (the still) which sits right on the ground. It has, in this case, a capacity of five hundred gallons. The sides are made of huge sheets of aluminum or copper, and both the top and bottom are made of plywood. There are three 2 by 4 supports inside the walls of the still which help support its great size (6). (3) is the firebox. The source of heat, in this case, is a huge gas burner mounted so that the flames point toward the still. Heat is drawn in, around the lower walls of the still, and out the flue (4). (5) is the furnace which in this case is a double row of concrete blocks sealed over (dotted line) with clay, or some other form of tight insulation. Space, of course, is left between the inside wall of the blocks and the outside bottom wall of the still for the passage of heat.
The cap arm connects to a large thump barrel which connects directly with the flake stand. There was no heater box in this particular model.
It is possible, by the way, to use a fifty-gallon barrel as the housing for the gas jets (3). It would be turned on its side with its end toward the still, and sealed to the concrete-block wall of the furnace with the insulating rocks, mud, and concrete.
Those who use them say that the groundhog stills are much hotter than the other varieties, and thus make better stills.
ILLUSTRATION 20 These diagrams illustrate perhaps the simplest still of them all—the “dead man” or “flat.” In all cases (Diagrams A and B) : (1) is the cap, (2) the still itself—a rectangular box, (3) the bottom of the box (the diagonally shaded area), (4) the firebox or source of heat, and (5) the flue.
There are several differences between them, however, that make them interesting. In A, the cap is a twenty-five-gallon barrel, and in B, a fifty-gallon one. The firebox in A is simply a channel cut into the earth. The still sits on the ground directly over this channel. A hole is left at the back to serve as the flue. In B, however, two 7 inch pipes sit inside the still box, surrounded by beer, with their ends protruding out both ends of the box. A long gas line is fed into each of these pipes, and its top surface is perforated in the manner of gas burners on stoves. This design supplies heat directly to the beer thus making a faster operation.
In A, the still stands two feet high, and six to eight feet long. A thin sheet of copper lines the outside of the bottom, and rises up two to three inches all around the sides. The rest of the box is made of wood. In B, the box is made of two 4-foot-square wooden boxes. They are mounted side to side, and the common wall is removed leaving a box four feet high, four feet wide, and eight feet long. The bottom is lined with copper as before.
Diagram A at the bottom shows how concrete blocks could be used in lieu of digging a trench in the ground. The dotted lines represent the insulation (mud, rocks, cement, etc.).
The operation of a steamer still similar to the one in Illustration 21 was described thus by one operator:
“It takes four men—a chief, a helper-pumper, and two haulers. We make our beer in six 4’ by 8’ boxes, and use two thousand pounds of sugar for every load. If we don’t get twelve cases out of every box, something’s wrong. And that’s only seventy-two cases a day. That’s not bad, but when I was running eight boxes I got ninety-six cases a day. And sometimes I could sell it for $60 a case. Not now. Price goes up and down—it depends.
“We use what we call ‘mule feed’ for malt, and we add beading oil to make it bead good. We use a radiator out of a Dodge truck in th’ flake stand, cleaned out good, of course.
“I just want to move th’stuff out—get it to th’ bootlegger quick as it’s made. That’s why I use haulers. I admit it’s not good liquor. It’ll give you a headache. But it won’t hurt you. I’ve drunk it myself before.”
Several things make a steamer still difficult. One is the amount of beer that must be on hand to begin with. From each 190 gallons in the Hodges Barrel, the yield will be approximately seven cases. Thus, in order to run off the ninety or more cases that can be run in a day, the main barrel has to be emptied and refilled about ten times. One man we talked to accomplished this with a pump and hose apparatus that he had rigged up. Contrast this with the old method of dipping the beer into the still with five gallon buckets and one can see how much things have changed. It still takes time, however, to prepare the beer. Thus a still like this one must lie unused for days at a time waiting for the beer to be ready to run.
Sugar presents another problem. Since anything over a hundred pounds must be signed for, sugar has to be bootlegged just like the whiskey.
In addition, the very size of the operation makes it more dangerous to run. Every effort is made to minimize the risk. One man, for example, told us that he never uses pegs in the outlet holes of his barrels. He has converted everything to valves. The reason: “Men who use pegs get in th’habit of hitting them three times whenever they’re putting them back in th’ holes. They hit that peg soft th’ first time, a little harder th’ next time, and on th’ third time they really whack it. You can hear those three licks on th’ thumper peg for miles.”
ILLUSTRATION 21 The Steamer: (1) is a spare tank for pre-heating water. Pipes (2) extend from the top of the furnace (6) into the bottom of the water tank, and as they get hot, so does the water. (5) is the main water tank. The coke burning furnace, which has a smoke stack (4), heats the water in (5) to the boiling point, producing the necessary steam. When this tank is empty, it is refilled with the pre-heated water through a valved pipe (3), and the spare water tank is refilled with cold water.
Steam from the main water tank, which is made of one and a third 50-gallon metal drums welded together, moves directly into a long thump rod, and via it into the bottom of a huge thump barrel (8) which is filled with 190 gallons of fresh beer at the beginning of the run. The barrel is a wooden Hodges Barrel with a 220 gallon capacity. From here the steam moves into a re
charger or relay barrel of fifty-gallon capacity (9) which can return “puke” to (8); then it goes into a dry barrel (10), and from there into another thump barrel (12) through another long thump rod (11). This barrel holds fifty gallons of fresh beer. From there the steam moves into a large heater box (13) which has the same function as those we have already seen, returning pre-heated beer to (8) through a valved line (17). The flake stand (14) is again, in this case, a large truck radiator. (15) is the filtering or straining barrel which is the repository for the final product. (16) is the water source for the flake stand. One informant told us that he could run ninety cases per day on a rig like this one.
ILLUSTRATION 22
Once two men were fixing a leak in th’ side of their still. One of th’ men was inside th’ still, crouched down, giving support from th’ inside; th’ other was outside with a hammer pounding away at th’ patch he was adding. Suddenly th’ man on th’ outside saw th’ law headed straight for him. Without a word to his partner inside th’ still, he turned and fled into th’ woods.
Th’ federal man came up to th’ still. Unaware that anyone was inside it, he took th’ pick with which he demolished stills and gave it a terrible whack, piercing the side. “Now you’ve ruined it,” th’ man on th’ inside screamed in anger.
HOW THE BEST OF THE BEST WAS MADE
as told by the men who made it
For this section, two men who are reputed to have made some of the best moonshine to come out of Georgia tell exactly how they did it. The process for making “pure corn” is the base of the discussion. Use of sugar in a run to increase the yield is also included, but in parentheses, as the addition of sugar would not allow the mixture to be labeled as pure corn whiskey. Use of a thump barrel is included for it does not diminish the quality of the product, and thump barrels were used during the old days.
Both of the men are now retired, and watch production today with increasing disdain. Here’s how they did it, from beginning to end, using a fifty-gallon still and seven 50-gallon barrels:
1. Go to the woods and find a good place. Make a mudhole which contains plenty of good, thick red clay for use in the furnace. Also construct any water lines needed for the flake stand.
2. Choose the corn. Do not use a hybrid or yellow corn. Use a good, fresh, pure white corn like Holcomb Prolific which will produce about three quarts of whiskey per bushel. Inferior brands will only produce about two and a half quarts per bushel. Get nine and a half bushels.
3. Put at least a bushel and a half of corn (but not more than two) aside to sprout.
In winter, put this corn in a barrel or tub, add warm water, and leave it for twenty-four hours. Then drain it and move it to the sprouting tub. Cover it with pretty warm water, leave it for fifteen minutes, and drain the water off. Put the tub close to a stove, and turn the cold side to the stove at least once a day. Each day add warm water again, leave it for fifteen minutes, and drain it off again leaving the tub close to the stove. Also transfer the corn on the bottom of the tub to the top of the tub at least once a day to make sure it all gets the same amount of heat. You should have good malt in four or five days with shoots about two inches long, and good roots.
In summer, simply put the corn to be sprouted out in the sun in tow sacks. Sprinkle warm water over them once a day, and flip the sacks over. It is also possible to sprout the corn in sacks under either sawdust or mule manure—both hold heat well.
Be careful, however, not to let the corn get too hot or it will go slick. When it starts getting too hot, stir it up and give it air to cool it.
4. The day before the sprouted corn is ready, take the remaining eight bushels of corn to the miller to be ground up. Don’t let him crush the corn or you’ll have some heavy material left that will sink to the bottom of the still and burn. Make sure he grinds it all up fine.
Take this meal to the woods. The last three or four days should have been spent building the furnace and installing the still. It should be ready to work now. Build a fire under the still. Fill it nearly full with water, and stir in a half-bushel of corn meal. When it comes to a boil, let it bubble for thirty-five to forty minutes. Cook it well or it will puke too much when cooking later. When it has cooked sufficiently, bring one of the barrels over, put it under the slop arm of the still, push in the plug stick, and let the contents of the still fill the barrel. Add a gallon of yet uncooked meal and let the hot contents of the barrel cook it alone. Make sure it is stirred in well. Move the barrel aside, and repeat the whole process until all the meal is cooked, and all seven barrels are filled. Return home.
5. The next day, get the sprouted corn (malt) ground up at the mill and take it to the woods. Use a miller who knows you and will keep your activities secret. He will take no toll for grinding your malt. He’ll take his toll out later when you are grinding straight corn again. You can also use a sausage mill.
In the woods, thin out the mash you made yesterday. This is done by standing the mash stick upright in each barrel. Add water and stir it in until the mash stick falls over against the side easily of its own weight. When all are thinned, add a gallon of malt to each barrel and stir it in. At the same time, add a double handful of raw rye to each barrel, sprinkling it around over the top. This helps to make the cap, helps the mixture begin working, and helps the final product hold a good bead. (If using sugar, add ten pounds to each barrel at the same time you add the malt.)
Cover the barrels. If they get rained into, your work is ruined. Return home.
6. The next day, the mixtures should be working. If one or two of them aren’t, then mix them back and forth with those that are, using a dipper. You want them all to be working at the same time so that they’ll all be ready to run at the same time. This liquid is now known as beer. Return home.
7. The next day, return to the site and stir up the mixture in each of the barrels to speed up their working. Home again.
8. About two days later, check again. At the same time, gather the wood you will need, bring in kegs, fruit jars, and whatever else you may need.
(On this fourth day, if you’re using sugar, add a half gallon of malt to each barrel and thirty-five to forty pounds of sugar to each barrel. Stir in and let the mixture work for five more days.)
9. If you are not using sugar, then the whole mixture should be ready to run on the fifth day of its working. (With sugar, it takes about nine or ten days.) You can tell when it’s ready to run by studying the cap that has formed over the beer. Sometimes this cap will be two inches thick. Sometimes it will only be a half inch thick, and sometimes it will just be suds and blubber, called a “blossom cap.” All of these are fine.
When the cap is nearly gone, or only a few remnants are left scattered over the top, the mixture is ready to run. The alcohol has eaten the cap off the beer. Don’t wait to run it at this point or the mixture will turn to vinegar, and the vinegar will eat the alcohol thus ruining your beer. It is better to run the whole thing a day early than a day late—you’ll still get mild, good whiskey. Appearance of “dog heads” also indicates that it’s ready to run.
[Note—one variation on the above process was also popular. Two bushels of mash were put in each fifty-gallon barrel, and cold water added. No cooking was used. This mixture would sour in three or four days and produce a crust. This would be broken up, stirred in, and the mixture left for another two or three days until it had soured again. Then a gallon and a half of malt was added to each barrel, and the mixture allowed to work another week. At this point, it was ready to run in the same manner as the other we have been describing.]
10. Now all connections on the still are sealed up with a stiff rye paste save for the cap and cap arm. The plug stick is inserted through the top of the still, handle first, and the handle pulled out through the slop arm until the ball of rags at the other end jams the opening.
Fill the still almost to the top (leave about three gallons off for expansion due to heat) with the beer. Put ten gallons of beer in the thump barrel.
Build up the fire underneath, and as the beer heats, stir it constantly with the swab stick to keep it from sticking to the bottom and sides of the still. Keep this up until it has come to a rolling boil and can thus keep itself stirred. Then paste on the cap and cap arm using the rye dough.
11. Chunk the fire easy, starting slowly, and gradually building it up in intensity. About fifteen minutes after the beer starts boiling in the still, the steam will hit the cold beer in the thump barrel and start it bubbling and thumping. On cold days, this thumping can be heard for several hundred yards through the woods.
When the thumping quiets, the beer is boiling smoothly in the still and doing fine.
Place a container under the end of the condenser. A funnel should be inserted in the container which is lined with a clean, fine white cloth on the bottom, a yarn cloth on top of that, and a double handful of washed hickory coals on top of that. The coals remove the “bardy grease” (it shows up as an oil slick on top of the whiskey if not drained off) which can make one very ill.
12. When the thumping stops, the whiskey starts. A gush or two of steam will precede it at the condenser end. This will be followed by a strong surge of liquid which quickly subsides to a trickle. On the second surge, “she’s coming for good,” as one man said.
Begin catching the alcohol on the second surge. (If it is being made with sugar, this first run will not hold a bead. Save it anyway.) Keep running the still as long as there is any taste of alcohol in the liquid being produced.
Then drain the thump barrel. Add the results of the first run—about ten gallons of backings. Then drain the still through the slop arm and fill it again with beer as before.
13. On the second run through, you’ll have good whiskey because the steam has gone through the backings in the thumper. It will be double strength. Keep checking it with the proof vial, catching it as it comes out of the condenser, thumping it in the palm of your hand, and watching the bubbles. When it’s dead, pull the container away. You should have two to three gallons of whiskey, the bead on which will be half under the liquid and half over it. (If you’re running sugar whiskey, the results from the first run on will be whiskey, and the bead will be two-thirds under the surface and one-third over it.)
Moonshining as a Fine Art: The Foxfire Americana Library (1) Page 4