NOTE. On 4/17/2012 I completely rewrote this recipe. I think it is a lot better now.
It is useful to think of chili powder as an American curry powder.
Like curry powder, chili powder is a blend of chile peppers and herbs and spices, and the actual blend can vary significantly from producer to producer. The best chili powders have multiple layers of heat and complexity that come from different kinds of chiles.
Remember, chile with an "e" is the pepper pod, and chili with an "i" is the powder and the meat dish in which it is used, Chili Con Carne (chili with meat), the classic Texas cowboy chuck wagon trail stew. Chili powder can be used in many recipes, from tacos to barbecue sauces.
Here's a simple recipe that beats the snot out of anything you can buy in a jar. It is a great opportunity for you to make your own signature spice blend. Want to add more chipotle or garlic powder, I won't stop you. Dried Scotch Bonnets? Why not?
Salt is almost always a component of commercial chili powder, but I have left it out of mine. I normally leave the salt out of my spice blends so I can use them on brined meats without oversalting them. Remember, you can always add salt, but you can't take it away. As background for this recipe, read my article, The Zen of Chiles.
Ancho is the backbone of most chili powders because they are mild and have a unique raisiny/pruney flavor. Chipotles are smoked jalapeños with significant heat and elegant smokiness. Pasillas are between the two in heat, and chocolatey, but they are harder to find so if you can't locate any, just add more ancho. Sweet paprika is made from very mild red peppers, similar to the bell peppers we use in salads. Alas, most of the paprika in the grocery has little flavor. Look for a high quality fresh Hungarian or Spanish paprika. Feel free to swap out the other chiles for your favorites. Just be careful not to go too hot. The secret to award winning Chili Con Carne is a chili powder that is complex and balanced.
You can buy powdered chiles, but the results are better if you grind them fresh. The size and weight of the average pod can vary significantly from store to store and from season to season. To help you plan, here are some conversions that are sorta average.
1 ancho weighs about 1/4 ounce before stemming and seeding, and makes about 1 tablespoon and 2 teaspoons
1 pasilla weighs about 1/4 ounce before stemming and seeding, and makes about 1 tablespoon and 1 teaspoon
1 chipotle weighs about 1/8 ounce before stemming and seeding, and makes about 2 teaspoons
Do this
1) Start by putting the whole chiles in a 350°F oven for about 10 minutes or until they are no longer flexible and they crumble easily. Leave the oven door open a bit so you don't knock yourself out with pepper gas when you open the oven (don't ask how I learned this). Cut off the tops of the chiles with scissors and shake out the seeds. Poke around in the chile with a knife to get the rest. Don't worry if a few get left behind. With the scissors cut the chilis lengthwise into two halves, and then into chunks about 1" square. Grind the chunks in a spice grinder, coffee grinder, blender, or food processor. I usually use my coffee grinder, but remember to clean it thoroughly when you are done or you'll spend the night on the couch (don't ask me how I learned this). Let the cloud of dust settle in the grinder for several minutes before you remove the top or your cries of pain will be heard blocks away (don't ask me how I learned this).
2) Pour all the powdered ingredients in a bowl or jar and stir them all together. The blend will still be useable for about a year, but the freshness and potency slowly declines.
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Make Yer Own Signature Chili Powder, Pahdna
NOTE. On 4/17/2012 I completely rewrote this recipe. I think it is a lot better now.
Like curry powder, chili powder is a blend of 
AmazingRibs.com is all about the science and zen of barbecue, grilling, and outdoor cooking, with great BBQ recipes and techniques: Baby back ribs, spareribs, pulled pork, beef brisket, steak, burgers, chicken, smoked turkey, lamb, barbecue sauces, burgers, steaks, rubs, and side dishes, with the world's best buying guide to barbecue smokers, grills, and accessories. It is edited by 
About Product Reviews and Best Value Gold, Silver, and Bronze Medals. These are highly recommended products based on features, quality, and especially value. Rest assured that when we recommend a product, it is really because we like it, not because someone has paid us to say so because we do not accept advertising from products we review. We purchase many products we review although occasionally suppliers send us samples. We have always been transparent about when we are reviewing a product sample, even before 
The prize for Best BBQ Tool at the 2012 The National Barbecue Association conference went to a simple inexpensive fridge magnet by Meathead. It includes the latest USDA recommendations as well as chef recommendations (and they often differ) as well as color photos of the different stages of doneness for red meats. The temperatures are the same for both indoor and outdoor cooks. 
With a $30 donation you'll get a 100% cotton brushed twill adjustable low profile cap with the AmazingRibs patch sewn on. I'll even toss in a small bag of BBQ'rs Delight wood smoke pellets. Click here for 
