newbiboozer wrote: Is there any reason for say Macs Bourbon knock off recipe only having only 3.5kg of sugar in a 30 liter wash as opposed to his Mac whiskey or rum having sugar as well as malt extract
Your question is valid with these recipes. As you picked up on, there are different quantities of sugar (raw+extract) between the two recipes, and therefore may yield different alcohol contents after fermentation. They are tried and proven, but it's all about experimentation...you can change up ingredients, just don't push the sugar too far or you'll stress the yeast with a high alc content and end up with fire water (IMO :D ).
If it were me, rather than dumping the grains into boiling water...insulate a keg/pot for a mash tun. Grind the corn (even put it in a blender) and throw that in the boiling water. Chuck the lid on and leave that sit for a few hours...add the wheat at it's appropriate temp in the mid 70's, and add the barley (cracked) at its conversion temp of 62-68 deg, and you'll end up with half the sugar from the grain for a much better flavour. Some would say this is too much effort, but it's really a bit of insulation, and monitoring temp every now and again for a few hours...
newbiboozer wrote: say for the BWKO is there any negative to increasing the sugar
I wouldn't think you'd notice a difference...unless you went too high (say pushing for 12+%ABV). I mean theoretically you're prob getting the same amount of flavour, but creating more alcohol, so maybe slightly diluting the flavour a bit...but realistically, I don't think you'll notice.