I've been making and using my own biodiesel for 2 years now and it is true, it's hard to justify the effort vs. what you save in fuel costs. Plus you have your initial investment in equipment. If you could find a second job that paid a little over minimum wage (no taxes taken out) and allowed you to work your own hours, you might actually be better off to do that and use that money to pay for diesel at the pump. But that kind of job can be pretty hard to find.
I brew mine in a friends shop and I brew enough for both his truck and mine. It takes me about 3 to 4 hours to make a batch (2 stage) so I can pull the truck in to the shop and work on it - maintenance and upgrades - while I brew.
I saved enough money the first year to pay off all my equipment. This past year has all been "profit". But it's still a "second job". On the other hand this past summer while everyone was paying $2. 80, and recently up to $3. 60 per gallon of pump diesel, we were burning 80% bio that cost us less than $1. 00 per gallon. There's a lot of satisfaction in that.
But with pump diesel at roughly $3. 25 these days - remember we don't run 100% bio, and in the winter we run about 60% - and the price of methanol being sky high these days, the margin is shrinking.
-Jay