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Re: Poly Cord
We used a piece of steel angle as a jig, clamping the two ends together. We used a creme brulee torch (a small butane torch) to heat the pieces together. As was pointed out earlier, they then need time to cool completely before they are used. Also, be really careful when you sand or cut off any bubbles or bumps. I recommend practicing on a few short bits. One of our mentors and one student became very adept at the welding, so we had one of them do it whenever we replaced the cord.
Side note: If you use polycord that needs welding, you are going to want to have a bunch of replacement lengths already welded when you go to competition. (In general no open flames allowed in the pit area.)
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Thank you Bad Robots for giving me the chance to coach this team.
Rookie All-Star Award: 2003 Buckeye
Engineering Inspiration Award: 2004 Pittsburgh, 2014 Crossroads
Chairman's Award: 2005 Pittsburgh, 2009 Buckeye, 2012 Queen City
Team Spirit Award: 2007 Buckeye, 2015 Queen City
Woodie Flowers Award: 2009 Buckeye
Dean's List Finalists: Phil Aufdencamp (2010), Lindsey Fox (2011), Kyle Torrico (2011), Alix Bernier (2013), Deepthi Thumuluri (2015)
Gracious Professionalism Award: 2013 Buckeye
Innovation in Controls Award: 2015 Pittsburgh
Event Finalists: 2012 CORI, 2016 Buckeye
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....you can't go to a single FIRST event without someone saying "Hey, Look! It's SuperNerd!" - [more] 
09-01-2012, 12:59
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