Help with "Uncle Jesse's Cooked Rye Mash" in wiki

[whackfol]

I am constructing a recipe for an all grain rye. There is a recipe by Uncle Jesse in the wiki which I was going to follow but I am stumped by some of his results. I can’t resolve the following:

Uncle Jesse adds 20 lbs of rye malt to 12 gallons of water and yields 10 gallons of 1.067 s.g. wort. I rant through the calculations using ppg and found the following: Twenty pounds of malted rye have a maximum of 580 points (20 lbs * 29ppg – Max from Palmers “How to Brew”). Divided by 10 gallons the maximum s.g. would be 1.058 and that assumes 100% efficiency. The s.g. he achieves reflects a 115% efficiency. When I brew, I get efficiency in the low 80% range at best. Any thoughts on how this can occur? It may just be a correction error.

Why am I interested? Well I am trying to plan for a batch with two 5 gallon stripping runs. Until I found this post, I was going to shoot for an original gravity of 1.06 (I use the 1.06 to 1.07 range suggested by Smiley in his book). To achieve this I need 600 points of sugar. Assuming 75% efficiency, I estimate I need 27 lbs of malted rye (600/29ppg/.75effic). If my efficiency improves to 85% I still only have an original gravity of 1.066. I plan to use Prestige Whiskey yeast and pot still.

In the wiki Uncle Jesse drains the wort off the grain and then ferments. I was going to add some rice hulls and ferment on the grain. Any thoughts?

Finally, since I have my calculator out, do the following calculations make sense? Assuming a starting gravity of 1.06, the potential alcohol is about 8%. If I assume there is no inefficiency in my distilling process, the maximum 100% abv. rye I can expect is 3.2 quarts (10 gallons * 4 qts/gallon * 8%). Deducing 3% for foreshots and 25% for tails (just rough estimates), I can expect a maximum of 2.3 quarts of 100%. Cutting to say a 45% abv finished product, the max I can expect is 5.12 quarts of rye. With the grain costing 32 USD and yeast about 8 USD, the total cost of just the liquid is 7.81 USD/quart.

Any comments on my question, my plan or my calculations would be appreciated.
Whack