I have a Vario chopper with the 5" "Sting" profile blade. Unfortunately, even if I adjust the quill guide to cut 4.25" - 4.5" feathers, I usually only get 1 really good fletch from a full length feather, so there is a LOT of waste. If you go with a 3" Blade and fletch 4-fletch, I think your money will go a LOT further since you're more likely to get 2 good fletches per full length feather. Problem is, I don't think there's a 3" banana option for the Vario chopper.
A burner might be a better way to go in the long run, but you'll probably have to burn your feathers outside.
Stump