Help with all grain mashing

[barbasol]

Hello all, first time poster but I have read a lot!!

I recently used the sour mash method http://homedistiller.org/grain/wash-grain2/sourmash" onclick="window.open(this.href);return false;" rel="nofollow that Jack describes with half cool water and half boiling water to mash a grain bill of 9lbs flaked maize, 3lbs flaked rye and 3lbs 6 row. I followed the procedure in the post and added 2 tsp of amylase with a packet of klv-1116. The grains absorbed so much of the water that it expanded and filled the entire 6.5 gallon bucket. So much so that I couldn't even take a clear liquid sample to get a gravity reading. I pitched the yeast anyways and was fermenting quite strong. After a week I still saw activity so I let it go another week. Finally I opened the bucket and it smelled great! Took a gravity reading at 1.015.

Here is where I ran into the most trouble. I racked off as much as I could which was about 2 gallons. I then attempted to strain but the remaining grains were so thick I was barely able to get another gallon out of it. This was done mostly by scooping into a grain bag and squeezing the heck out of it or pouring into a strainer and using a spoon to push the wash out. A lot of work for only 3 gallons. I ran through my still which is a keg with the pot still head from brewhaus. The final product came out good although it was overwhelming with the corn flavor which is the second issue I am seeking to address.

My plan is to step up the scale i was working at and here are where a couple questions will come in. I now have 16lbs flaked maize, 8 lbs rye malt, 4lbs 6 row and 1 lb of husks.
Question: I am thinking to either use my same method in a 30 gallon bucket. Should I proceed or maybe put the maize in a straining bag first and ferment in the bag? I switched out the flaked rye with rye malt to cut down on the oatmeal effect. That is also why I got the husks, to help with straining. Or I also thought about fermenting the rye and barley in one bucket and the maize in another in a grain bag and then combining the washes afterwards? (this doesn't seem like a great idea.

My main goal is to have more mash to work with. Am I using too much grain? I was going off of 3lbs grain per gallon of water.

I also changed the grain bill to mellow out the corn flavor. Will the malt rye change the flavor profile vs. flaked rye in yalls experience?

Any help is appreciated. Sorry if the post was too long. Just trying to get all the details I can remember.

[Dnderhead]

most start with 1 1/2 --2 lb per gallon..the rye does not help.it should be done with a steped mash or use malted rye.

[barbasol]

This time around I am using rye malt instead of the flaked

[rubber duck]

That recipe has way to much grain, as you found out it's a pain to work with a grain to water ratio that high. Cut your grain in half.

On the issue of straining I use a fruit press. A paint straining bag can be used, using it with a bucket full of holes inside of another bucket to make a false bottom, works pretty well. It's still some work to squeeze it out but it will get the job done.

I wouldn't use your fermentation idea, your right it's not a great idea.

If the flavor is overpowering try double running it.

[barbasol]

Thanks rd. definitely will limit my grain to water ratio to 2lbs max. I believe I read another post where you used the fruit press. Not quite there yet but a false bottomed bucket should do nicely.

[Prairiepiss]

You can drill holes in the bottom of one bucket. Fill another one with water and lid it. Use to one filled with water as the press. The water weight will make it easier to press.