Was burning some feltches tonight on my home-made fletch burning jig and thought that I might post the method I use for those who may not have used it before. It's nothing new of course but I thought some might find it useful and want to give it a try. The nice thing is, in a few minutes you can make yourself a custom jig any shape or size. I like to burn mine 4 to 4 1/2" long because then I can get two fletches from one feather.
Here's a view of the front and back side of a jig. Just a couple pieces of 1/8" thick scraps. Glue a popsicle thick for a straight edge at the bottom of the jig. Fabricate a top half to the jig that is just slightly smaller than the bottom half. This allows space for the vane of the feather.