You & sound a little alike as far as doing thing on our own. I rarely post here for a number of reasons, but mostly because I get tired of reading what can't be done. I did it. I'm not a lawyer, but do have business degree & a licensed DSP 100ft from my garage. Possibly the smallest in the country. I make a small profit, but have a straight day job, too, so making liquor is not an every day thing for me.
As mentioned above I have a DSP on my residential property, no rezoning required. However, I did need a township zoning variance, a new physical address and a rental agreement between myself and my LLC among other things. This was done 3 years ago, so my recollection may be fuzzy but i have since helped 2 other rural distillers get set up on the same property as their house. If you need different direction, I know of another distillery that is located on the first floor of a dual use building with apartments on the 2nd floor.
The big things that the TTB will absolutely require:
Secure the revenue, meaning a secure building to lock up the liquor WITH a separate entrance to the bonded area that leads directly outside. They do not want to know what is happening in the unknown 500sf in front, or your retail tasting area. Donot even label it on your sketch. Just write "non-bonded area" and move on.
A permanent line of delineation that is easily distinguishable and "difficult" to remove which discriminates between your residential yard and DSP, including a standoff of at least 8ft from the building containing the DSP. Driveway, fence, hedgerow...something that is not easily removed.
You will need a separate physical address. I had to contact my county engineer's office. Probably the easiest out of all these.
City people or non-rural or commercial addresses don't need to worry about this. It's already measured in the plat book. But...measurements to the building in the nearest 6" increments from a permanent known feature. This means the surveyor's pin on your property, or closest pin to it. It has to be from the pin, no other feature will suffice. MUST BE SURVEYOR'S PIN. I can't stress that enough. It's probably on the road and may be half mile away, but you need to measure from that point, then around your building. I'm going to guess that more than 99.5% of distillers don't know how to survey and use a transit, and will have to pay for it to be done by a licensed surveyor. I am fortunate to be in the half percent who has a transit and was trained to use it. Of all things that foul "residential DSP's" these measurements are the most critical and usually screw up the deal. Read a property description in the deed recorders office to get an idea what I mean if you're not familiar.
Your DSP must be a minimum distance from your residential structure, including attached features such as porches, decks, garage etc. That distance is between 100ft and 50ft depending on the agent, size of your DSP and time of day among other things. I'm between 50 and 100ft, but my DSP is small, and my nearest neighbor is over 1000ft away.
One last thing, callaheas. I got lucky & talked with a very nice lady who basically hand-carried my packet through, answered and questions i had, and previewed my permit app before I sent it to streamline everything. Approval to exactly 45 days, for a 1-man, no investor DSP in rural Ohio in 2015. Your mileage may vary, good luck.