The result was pretty good but the process was pretty hazardous and there were still problems with moisture in the salt. So taking in some suggestions and with a bit of lateral thinking I decided to try a different method.
I am currently staying in the middle of nowhere away from any shops so I had to use what was laying around. Luckily I had some salt and some chillies, so that was enough for a proof of concept.
Now a quick warning (the first one) - If you live with people it may beneficial to explain that you are in fact making Chalt and that you have not resorted to cooking Meth for money (you will see what I mean later).
The second warning: The fumes from this process are, although I think pretty harmless, quite noxious. I had to abandon my hob top boiling because where I am now there is no extractor and I was choking everyone in the house. I will explain how I tried to get around this during the instructable.
Anyway here it is Chalt 2: "Salt but not as we no it."
Step 1: Chillies, salt and water (and a little dash of vinegar)
Okay, get your chillies, chop 'em up and put them in a pan of water. Basically you are trying to infuse as much chilli essence into the water as you can. I added a bit of vinegar to the water because I thought it might bring out a little more of the chilli. Take the pan to the boil.
After around 10 to 15 minutes of boiling heavily clutch at your throat and start choking. Let water stream from your eyes and snot roll from you nose. Once everyone in the house is doing the same then this stage is complete. (Note: you may want to skip this step and infuse slowly in the oven as I decided to half way through. As suggested by someone in my last instructable).
Step 2: Infusion and straining
At this point re-heat the water and dissolve salt in until saturation point is reached. That is the point at which no more salt will dissolve in the solution.
You now have you Chalt solution.
The second photo shows the strained liquid in a silicon baking tray.
Step 3: Baking
The result is these rather dirty looking crystals. I ground them fine and stuck em in the oven again to get the rest of the moisture out. I left it to cool and there you have it "Chalt".
I think next time longer evaporation times, maybe a little crystal garden. Basically, I want big crystals.
Have ago and give us some feed back. any ideas on making cleaner looking Chalt.