Hello, iremain69. Welcome to THP.
Disclaimer- I'm not a process authority, just a licensed sauce maker. This is just my opinion.
Based on the information you've provided, there are a few red flags I see. The biggest is that the fresh vegetables are not all cooked. It looks like the peppers and garlic were blanched, but not the fresh onion? Raw veggies of any sort are low acid items and either need to be (1) fully cooked and used in a fairly acidic sauce, (2) pressure canned, or (3) if left raw, the acid/pH of the sauce needs to be really low to prevent nasties from growing.
Without knowing the exact proportions of your recipe, it's hard to make an educated guess as to the pH. Having "made the sauce this way for the last 2 years and not had a problem" could just mean you got lucky before. The natural pH of the chiles can change from year to year, from different sources, and from variety to variety. The chiles may have had just been just low enough pH so your sauce was previously OK.
Also, since this is a homemade sauce, I'm guessing you didn't weigh the ingredients and follow the exact same proportions. Something like ...the size of the onion....can be enough of a variable to change the sauce. If you used a slightly larger onion this time than what you'd used before, that could of added just enough pulp to the mix that the pH was no longer as low as it was previously, and therefore not low enough pH to keep the nasties from growing.
Without knowing the exact proportions of the ingredients, not knowing the pH, and knowing the sauce was not thoroughly cooked and hot packed....I'm sorry to say, but I'd pitch it.
it's a lot of work and $ down the drain, but is it worth it? Hopefully, at this time of the season, you can get some more chiles and make another batch. On the bright side, you can re-use the bottles with a fresh lid.
Have you seen the Making Hot Sauce 101 thread? It talks about re-using bottles and caps, and how to do it safely.
once again, just my opinion-
salsalady