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First, I would recommend just using a fire, and watch the smoke. I've never noticed flames out of the hole, just watch when the smoke turns from gray to white. Then take out of the fire and let it cool.
I've also never covered the hole and have never had a Flashback with it, And I don't believe it would be a problem so long as you keep it away from the fire.
Apparently, what we are talking about in general is tinder, and there are a significant number of artifacts out there in regards to it. One of the more interesting is the notion of a tinder stick, which is a metal tube that has a cotton (or linen, or jute) cord in it. You light one end of the cord, let it burn and then pull it back into the tube, which extinguishes it and makes it into tinder. Then, when you need a bit you push the charred end out and go to it. Isn't technology wonderful?
The thing that must be remembered is that in the days before electricity, the primary energy source for heating and cooking, and to some extent light, was wood fires. Making them was a daily thing and technologies evolved to support the process.
Boyscouts used to sell a metal canteen of this shape. Why plastic? Take cover off and use as fire starter lens. Even half empty.
Being currently under employed, I can't do this myself.
I don't know how I managed to go almost 30 years of camping without ever learning
about this stuff, but I digress. I'll be making some char cloth soon and certainly
like the idea of using cotton balls. These will go great with the flint strikers I had
a blacksmith make for me yesterday.
I think you could char polyester and hence polyester blend cotton balls, but I think the straight cotton balls are the best bet.
Plastic tends to not be that good.
Idea two: Use Gun cleaning patches for char cloth.
Cut the denim to fit the can as many layers as will fit.
The can makes a handy carrying case and the "sheets" of charcloth just peel off.
And you can make more on the fly in the field with your can.
Keep it in a plastic bag with your shavings and dryer lint and firesteel and you are good to go.
I used a tuna can and cotton balls because I think more people will have those than shoe polish and gun cleaning patches.
Now I'm interested in seeing a comparison of how well the lint works before and after being converted to charcloth.