heat.(are you using EZ BODY?) if you use e-z body instead of the cheap stuff the conomo's and corsairs will come out neater when you (dare i say) torch the edges. it; funny you should mention it as it does it but putting the mylar close to the heat or flame gets it somewhat neater.( after you've tied you should take out the thread on both sides. e-z body mylar (melts) clearer than run of the mill stuff from the fly shop (just an observation) you could use a cheap solder iron or a jet lighter. but it makes no mind to me as i purposely make fly;s to be battered up as they work better after a bluefish mangles em. just something about that fluffed out deceiver that triggers a bite. if you are looking to sell fly;s then the finished product should by all means look perfect. you surely don;t want to leave large knots/bumps/bulges/twists or imperfections on any part of the fly let alone the business end of your terminal tackle. ie: hook eye or near it. that includes plugs and jigs as well. sometimes i get a good thread in here, welcome to the fanatical world of 247
btw, you should (if you didn;t already) get his book!