pic: The rig for fusing polycord we settled on.

A 3.5" portable vice, scrap aluminum plate and a stock propane torch. Wearing gloves and glasses and with minimal fumage, we were able to get all of our polycord strands done up pretty quick. All you do is just heat the plate, put the end on the butt the ends up.

The kids are still trying to break the first piece we made.