Question number 1: How much time are you wanting to spend? The method you use depends a lot on that.

I'm sure you will get some good answers to your question from the good people here but if your were to do a Google search for making chili sauce there are a number of sites out there with recipes.

Greg
Nevada

Here is a good idea:
http://mostlycajun.com/wordpress/?p=1718

the only thing i disagree with is the author's statement that "you are only interested in the vegetable not the vinegar".
I personally like the spicy vinegar as well as the vegetable!

hope that gives you an idea that you can easily work with
Danny

check out the harvest forum they have good info there plus use search like google for hot pepper sauce recipes and sites that can lead you to some excellent recipes.

Here's how i do mine:

{{gwi:1209499}}

The major ingredient is patience.

Here is one that is quick and easy. I usually quadruple the recipe. Also, I use a bunch of different kinds of peppers.

Fire Water
Recipe courtesy Tyler Florence
Prep Time: 5 min
Cook Time: 30 min
Level: Easy
Serves: 1 cup
Ingredients
 12 cayenne chiles, stems removed
 2 garlic cloves
 1/2 yellow onion
 1/2 lemon, juiced
 1/2 cup white wine vinegar
 1 cup water
 1 teaspoon salt
 1 teaspoon sugar
Directions
Place all ingredients in a heavy saucepan and slowly bring to a simmer over medium heat. Simmer for 20 to 30 minutes. Remove from heat and cool slightly. Pour the mixture into a blender and puree until smooth. Pass the hot sauce through a mesh strainer lined with cheesecloth, if desired.
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