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Re: polycord problems
Our team did it with a small torch and skillful hands: a mentor carefully holding the two ends in front of the torch ad pressing the ends together until the fused into one. This left a large lump of melted polycord around the fused point, so we cut off that part with a knife.
It takes practice, but you definitely don't need to spend $600 to get the results you are looking for.
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Vivek

Treasurer, Senior Build Officer, Saints Robotics 1899
Seattle Olympic Regional Chairman's Award 2011
Seattle Olympic Regional Winner 2011 (Thanks 2990 & 3393)
Seattle Olympic Regional Best Website Award 2011
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