I agree Eric. When I first started brewing, a friend asked when were we making whiskey. I told him that the learning curve was too steep on something that would take years to be ready. I brewed twice a month my first year, and it took all of that to learn to make craft quality beer. I would just be sampling my first batch of aged whiskey now.
That's not true at all (except perhaps for the part about learning to make good beer/wash first)... you can make high quality American style whiskeys in as little as 6 months. You have to understand 1) commercial whiskey distilleries produce a CRAP product that needs a lot of aging and charcoal exposure to mellow out... they run hot and fast and pump the product out in volume 2) Relationship between temp cycles and aging, 3) think about surface area/exposure... small barrel whiskeys always taste like crap because the ratio is way off...
and back to #1)
Whisky produced in the U.S. at not exceeding 80% alcohol by volume (160 proof) from a fermented mash of not less than 51 percent corn and stored at not more than 62.5% alcohol by volume (125 proof) in charred new oak containers.
the basic premises of pulling your whiskeys at <160 proof from the still is just nonsense... it adds to the crap starting product and its inclusion in the definition of bourbon is historical garbage. If you make many finer cuts and blend back only what you like, you will end up with a far superior starting product that will require less aging to mellow. Take a look at a typical pot run as illustrated below. How do you separate the hearts from the heads and tails? How do you separate the different components of the heads and tails into determining what is and isn't desirable? It's not truly possible, is it? They're all smeared together. The more coarse and lower purity your cuts are, the more "smearing" that is occurring outside of your control.
Now in a more controlled run in a high reflux still, you will have much more obvious delineations between the different components. And through trial and error you can determine what is and isn't suitable for your needs.
For aging, char some staves all the way around and age in stainless. Allow some air exchange periodically or via some small hole/breathing valve thingy of your choice.
There are quite a few here (including a couple mods) who can vouch for my... ahem... "knowledge" on this...
This is more labor intensive, but at small scale, what else is it but a labor of love?