Long overdue update!
When we last checked in I was in the process of husking the hazelnuts, and had finally separated the obviously inedible ones from the possibly edible ones. I set up a drying station which consisted of the nuts spread in a single layer on top of paper towel over top of an open camping cooking rack, propped open with a glass and a paper towel roll, with most of the edges leading to a towel-lined box so the grubs would emerge, crawl off, and be collected somewhere they couldn't chew through to escape. While they were drying, I took a random sample of 12 nuts and smashed them open - 1 in 6 were edible, the rest had been chewed through by grubs to some extent. At the very least, it's easy to tell the edible ones apart from the inedible ones due to colour, texture, moisture, and probably taste (that said, I didn't eat any of the inedible ones so I can't confirm that but I think it's safe to assume).
After two weeks, the grubs were bagged up and given to some friends in exchange for some fresh eggs, and I went through the remaining nuts by hand and removed any that had any holes, were too small to contain anything, or were still green. Similar to the sample I took a couple weeks prior, only about 1/6 of the nuts that sunk in the sink test ended up being edible.
Would I do it again? Probably not - in addition to receiving hundreds of mosquito and tick bites while out harvesting them, there's so many wild critters also looking to eat them that very few of the ones I picked were edible; about 20% passed the sink test, and 17% passed the drying test, for a whopping result of less than 4% of what I picked being edible. They tasted lovely but so much work for such a small return just isn't worth it when not in a survival situation - I'd have been better off picking chokecherries and making some jam or wine.
That said, I'll post my updated American Hazelnut Harvesting guide here:
1) American Hazelnuts (usually) ripen faster than most other nuts, usually ready by mid/late summer to early fall, that is, between mid-July to early September depending on climate and species/cultivar.
2) American hazelnuts can be picked when the involucre (outer casing) is starting to turn brown up until it has completely turned brown and peeled back, but can be eaten raw when still green. The longer you wait, the lower your chances of it being edible.
3) Unlike beaked hazelnuts, you can safely yank them right off the branch, although twisting/snipping them off will cause less damage to the plant.
4) If they have holes in them, they've already been eaten by grubs and are inedible and can be left on the ground for other animals to eat or composted.
5) When peeling off the casing, place a batch of hazelnut clusters in
hot water, then remove the casing (place aside for composting) and leave the nuts in the water. Remove any nuts that float and add to the casings to be composted.
6) Place the remaining nuts in a single layer on a drying rack to air out for 1 to 2 weeks, with something underneath to catch any emerging grubs. Alternatively, the nuts can be dried for 2 to 4 days in a dehydrator, removing any emerged grubs daily.
7) After the hazelnuts have sufficiently dried, remove any nuts that have holes in them or are blemished, any nuts too small to be edible, and any nuts that are green but still hard.
8) Crack open and enjoy, or keep for up to 6 months, after this point they'll start to dry out and become less palatable.