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May 4, 2013

How to Make Your Own Aged Whiskey

Barrel Aged Whiskey

How to Age Whiskey

Barrel aging offers many benefits. It is responsible for much of the flavor found in aged spirits. It also makes spirits much more palatable by removing some of the chemicals that make whiskey taste "hot" or "harsh."

To spot aged whiskey, all you need to do is evaluate the color of the spirit, which is easy to do since almost all whiskey bottles are clear. Aged whiskey can be golden colored to caramel, to dark brown.

The color of whiskey is confusing to a lot of people. You see, most folks think that "white whiskeys" are clear because they're made with a different process than colored spirits. That's only partially true. Yes, the typical recipes for all types of spirits vary, but the actual production process and ingredients are very similar, and in some cases, exactly the same.

Brown whiskey (everything from Jim Beam Bourbon to Jameson Irish Whiskey) comes off the still as clear as mountain spring water when it's initially produced. That's right, initially, all whiskeys look exactly like a white whiskey right out of the still. It isn't until whiskey is aged in wooden barrels that it takes on darker colors. 

Why is Whiskey Aged?

Why is whiskey aged? Well, similarly to many other longstanding traditions, the practice of barrel aging grew out of necessity. Early producers and transporters of wine used wooden barrels to ferment and then ship their products. Though, the practice has withstood the test of time because, coincidentally, long term storage in barrels has a positive effect on the character and smoothness of most alcoholic beverages. Early consumers of these beverages noticed that (typically) the longer the beverages had been stored in barrels, the better they tasted. Thus, the demand for barrel aged wine and spirits was born.

What Happens During Aging?

During the storage period changes in temperature and humidity cause alcohol to be pushed into and sometime sucked out of out of the wooden walls of aging barrels. As this natural ebb and flow occurs the alcohol is gently filtered by the wood. Some of the whiskey (typically lighter and more volatile compounds) actually evaporate through the wooden container walls (which is called the angels share). At the same time, vanillins and tannin are extracted from the wood and impart their unique flavor and color to the whiskey. The cumulative effect of the intricate process of barrel aging is a final product that has more character and less bite than the clear, fiery spirit that went into it.

How to Age Whiskey

Barrel Aged Whiskey Kit

There are two ways to age whiskey at home. The most traditional method of DIY whiskey aging is to purchase or build a charred white oak barrel. To prep a barrel to be used for aging, make sure to first fill it with warm water and leave it sit until the wood swells enough to prevent leaking between the staves. The hydration process could take anywhere from a few hours to a few days. It's very important that you do this to prevent your spirits from leaking out of the barrel when you initially fill it. Once hydrated, drain the water then fill it with clear, un-aged whiskey and leave it sit for a couple of weeks. Remember, it's illegal to distill your own alcohol for consumption without a distilled spirits permit. But no need to fret, there are plenty of un-aged whiskey options to be found at any liquor store.

oak aging stickThe easiest way to accomplish aging is to add charred American white oak sticks or shavings to a jar or bottle of spirits (such as the product picture to the right). The charred wood will naturally absorb and release spirits contained within the vessel, allowing the wood to impart its flavors to the spirit. However, this method will not allow the volatile compounds to escape by forcing their way through the container walls (as happens during traditional barrel aging). Accordingly, one must regularly open and close the vessel in order to allow trapped alcohol vapor to escape and be replaced by air. 

How Long Does Oak Aging Take?

Fantastic results can be achieved in a relatively short amount of time with home aging. This is because the surface to liquid ratio of DIY aging kits is much higher than that of barrels. The commercial whiskey industry ages their product in 53 gallon barrels to achieve a better economy of scale. In small batch aging using oak sticks in a small container there is more wooden surface area in contact with the whiskey. It's less efficient from a materials standpoint (which is why commercial distilleries age in 50+ gallon barrels) but much more efficient from a time and aging standpoint. All of that extra surface area rapidly accelerates aging of the spirits. Aged perfection that takes years to achieve in 53 gallon barrels can be accomplished in a matter of days/weeks with charred oak sticks.

The benefits of aging can be negated if too much of the wood flavor is imparted to the whiskey. "Over oaking" your spirit is a definite possibility. Every few days or weeks, a small sample should be drawn from the vessel to ascertain quality of aging. Once the whiskey has achieved the color and smoothness of your liking, transfer it to a glass bottle or jar for long term storage.


    Posted by J Neiswander on July 21, 2015
  • I am using a commercial 2 Liter oak barrel and after preparing the barrel as directed I filled it. I has been 3.5 weeks and I sample weekly and turn barrel 45 degrees left and right weekly . I top off the barrel after testing. After last tasting, the flavor is pretty good as compared to the 110 % starting spirit but the color is very very light compared to average bourbons. The manufacturer of the barrel suggested about a month. Any ideas?

    Posted by David on July 09, 2015
  • Just starting love the articles!

    Posted by jd jones on May 19, 2015
  • Another question if I may; I’m in the process of losing my ‘distillers virginity’ as I write this (made my first mash yesterday). In the aging process, using charred oak, will the finished product be clear, or will I need to filter it through a medium or cloth?

    Posted by Ran Ricard on October 04, 2014
  • There are several different varieties of white oak. Is any one better than another for making chips and aging whiskey? I have a large Post Oak (White Oak family) in my yard and offers me plenty of product to work with.

    Posted by Ran Ricard on October 04, 2014
  • Hi ya where can I get barrel for aging 5-10 gal moonshine in, at good price?

    Posted by kenny on March 07, 2014
  • what about using your typical smoking woods? like apple wood, cheery wood, orange wood? what kind of affect would this have?

    Posted by mike on February 05, 2014
  • Just an idea. Mason jars with wood chips as described above. Then get thin oak board that is often sold in hardware stores for cupboards. Cut out circles to replace the tin plate on the jar lid. Now the jars can breath. I have not tried, but should work. Will call it “aaron’s hybrid aging method”…

    Posted by aaron on January 18, 2014
  • when i put whiskey in my 2 liter oak barrel it is coming out black after about 30 days. i tried to filter it through a coffee filter and the charcoal is so fine it doesnt catch it. is there a solution or a process that will stop this. i cured the barrels as directed. this has happened to 4 different barrels purchased from the same company at the same time.

    Posted by Don Schmidt on December 03, 2013
  • Smaller size barrels…5, 10, 20 gal., where can they be purchased?
    Also……is there a place to purchase small barrels that have been used in the production on rums or cognac?
    Oh…..this site is awesome…best collection of knowledge about whiskey I have ever come across.
    Great things being done here…!

    Posted by Ted on October 02, 2013
  • Has apple wood, maple or pecan wood made barrels ever been used to age moon shine or commercial made whiskey.

    Posted by Ted on October 02, 2013

    Posted by MOOKIE on August 19, 2013
  • Independent Stave Company – Lebanon, MO – different woods are used for the different barrels
    53 gallon barrels
    Classic @ $139.50
    Select @ $155.00 *toasted heads are an additional $15.00
    American Oak @ $255
    American Staves w/ French Heads @ $360
    French Oak @ $660
    European Oak @ $570

    A&K Cooperage – Higbee, MO – Missouri White Oak Barrels
    30 gallon @ $265.00 *His sales pitch was that he’d discount the barrels if we picked them up ourselves.
    40 gallon @ $275.00
    60 gallon @ $340.00

    The Barrel Mill – Avon, MN – American White Oak Barrels
    30 gallon @ $310 (including shipping)
    *those infusion spirals are really interesting… I may want to look at those if Grandpa’s barrel is going to hold water.
    The gent at the Barrel Mill is pretty knowledgeable about how the whiskey is aged. He said if the the oak barrel is old enough it might not give off any flavor but what’s more important is the filtration from the actual char of the barrel. Pop in a few of the infusion spirals and your barrel is as good as new. Anyway, this is what I stumbled across today.

    Posted by Mac on June 20, 2013
  • Pretty interesting article. :)

    Posted by BMC on May 05, 2013
  • The best tasting whiskey I make is aged using charred muscadine vines. I strip the bark, then carefully char it (it will burn completely up quickly if you are not careful) in 4" lengths. Add it to the jars and allow it to breathe once a week.

    Posted by Earl Paige on May 04, 2013

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