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Gave this process a try as PianoMan originally posted. Dissolved 6 lbs of Amber DME into 5 gallons of water. Added about an ounce each of Amarillo, Cascade and 1/2 oz of Simcoe into about a gallon of boiling water with half a cup of brown sugar. Boiled for about 10 minutes and let simmer on low for 15 more. Dumped in fermenter, stirred anp pitched safeale 05.
Easy peazy.
How did that process work for you? Although I've had success, I do believe a heating to 180F is probably wiser. Been brewing big beers all year long so no 'no boils'