by Part-Timer » Oct 13th, '08, 19:22
I've never done this, but I can think of two ways, one of which will definitely work, but is a bit of a pain. Split the card, removing the front layer (I am assuming you use Bicycle cards, which have three layers), then burn the back using something like a cigarette or a hot piece of metal. I suspect the warping is because the heat from the flame is affecting much of the card. If you can quickly burn the card it might be less likely to warp. Then, reassemble the card.
The other way (which I think makes sense, but might not work), is to clamp the face of the card onto a clean piece of metal. Then burn the back. Again, I think using something that will put a narrow spot of intense heat will work better than a lighter. My theory is that, on the face side, the metal will conduct the heat away, reducing the chances of scorching.
I have no idea if it actually makes sense from a physics point of view!