I've got a few as well...
there was the time I was drying habs in the oven and had the heat a bit too high, it was like the house had been shot full of police pepper-spray canisters. my wife and I had to evacuate the house for an hour because we couldn't stop coughing, sneezing and burning eyes.
or the time I was making sauce in the kitchen, my wife had gone out shopping and her parting comment to me was "don't make a mess". I had the lid on the blender which was full of red habs. our pet cockatoo was on his stand next to me watching the goings on, every now and then I'd slip him a hab to munch on - he likes all chiles! I took the lid off the blender to add some more ingredients. forgetting that the thing was plugged in and turned on, I picked it up by the base and in doing so I depressed and held the pulse button. needless to say 3 seconds of about 20zillion rpms successfully sprayed chunks of hab everywhere. not only that but there was an immediate release of chile gas. I was rushing around trying to clean up while coughing and sneezing my head off saying "f***, f***, f***". the cockatoo was screeching his head off. what a disaster. funny thing was I managed to clean up everything except for one small chunk that chilliwoman found as soon as she walked in. now I'm forced to make my sauces, powders, jerky, sausages and other experiments on the back verandah.
I've also blended habs and birdseyes and released powder and dust into the air - one time it was like a sand storm.
I've got a million 'burning myself while making sauce stories' too but I guess we all have them. you know, the one where you get some invisible juice on your finger then manage to touch every sensitive part on yours and your partners body, it's got amazing adherent qualities that capsaicin - it's a bit like the scene from The Party with Peter Sellers when he gets the caviar on his hand. ever had hot hab mash splash up and burn you while bubbling away in the pot then had the immediate reaction to lick the hot sauce off your hand/arm only to ingest hot concentrate?
ok, someone else's turn.