Pepper spray is made from oil of capsicum.
The process for making it is very similar to making hash oil or many other essential oil extracts including food flavorings that are oil based.
One can make it from dried or fresh chiles. Personally I am fond of the fresh method for reasons given below.
Using fresh chiles most recipes call for using a food processor to finely chop the chile, however this process will still leave behind a quantity of oil in the product. This is because the purpose of the chopping process is to rupture the plant cells of the vegetable matter to allow for easier extraction of the oil.
A better machine to use at this initial stage is a food juicer.
One extracts the juice from fresh chiles, and seperates said mixture from the pulp.
The pulp is then treated with a emulsifier. Many recipes call for the use of alcohol as oil is somewhat soluble in alcohol (see HEET fuel additive).
For food grade use, one should only use ethyl alcohol as the emulsifier. Basically you seep the pulped chiles in alcohol, (or a petroleum product) for a time and filter said liquid from the product. The liquid juice can also be recombined with the alcohol extract or used on its own immediately.
Once this filtered liquid is achieved where the oil is held in suspension of the alcohol (or petroleum) one simply evaporates off the volatile elements of the solution (water and alcohol or petroleum like white gas, butane etc)
This process of course has fire risks so one must take appropriate precautions.
I might add that you will need apropriate personal protective gear including goggles and gloves as well as a wash station.
A good method is to use a solar oven type of box to evaporate the liquid portion, it is slower but no open flame or hot heater elements to serve as a ignition source as the flash point of the evaporating distillate is quite low making easy ignition.
The resulting oil will have a reddish color from residual chile compounds, but will not affect the end product potency much.
Here is a graphic for commercial grade extract.
Pure capsicum can be further refined using standard lab procedures which is beyond the scope of this article.
Other methods are gel capsules (provided all water is removed)
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Now's the time to make enough hot pepper oil for a year. ... "220 ml Bottle of Chili Pepper Flavored Organic Olive Oil Regular price: ...
... or by individuals for personal defense. Pepper in vegetable oils, or as an horticultural product ... Capsicum fruits and peppers can be eaten raw or cooked.
Other constituents present include carotenoids (capsanthin, capsorubin, β-carotene, lutein, zeaxanthin, etc.); fats (9-17%), proteins (12-15%), vitamins A, C, and others; and a small amount of a volatile oil made up of more than 125 components of which 24 were How does Capsicum Extract work?
Ethyl Alcohol, 70% ACC# 91791 ... Flash Point: 16.6 deg C. Flammable liquid and vapor. May cause central nervous system depression. Causes severe eye irritation.
This is how to distill herbs for oils. I found this idea at http://www.ehow.com/how_5604828_make-.... I'm the host and my nephew Terrell was the ...