So I was give several spools of wire that has the same behavior. It came from a commercial supplier who I wont name but probably the same ones Melvin, RSM and everyone else is buying them from.
I think there are only a few manufactures of this wire. They may wind it different depending on the customer specifications.
I think the lines were wound on the spool from the end, rather than winding them on the spool ,and that causes the problem.
From my experience winding Kevlar, sometimes the spool is stationary and the line is wrapped on the spool, sometimes the spool spins.
My first attempt was to go down and back around a fence post. I did not restrain the cut end and had a tangled mess.
After I screwed up that set I can now make line sets by following the process below. It releases the built in twists in a controlled way.
1) put a termination on the line
2) Hook the end over a nail and run out your length + 12"
3) Hold the free end tightly in one hand. DO NOT let GO.
4) Cut the wire offset cutters or real good diagonal cutters. Make sure you cut ALL the strands DO NOT LET GO of the free end! it its frayed cut it again.
5) use the other hand to grip the wire about 4' from end. take the slack out of the wire so it cant tangle.
6) slowly loosen the grip from the free end but using both hands restrain it and let the residual twists undo themselves. DO NOT let the wire snarl up.
7) Put the other termination on
walk out any few twists that might be there.
9) repeate
I may waste a few inches of wire and it takes extra time. But the wire is fine and the method works.
I wonder if a little ca on wires in the extra cutoff wire would prevent the cut end from fraying.
I did breaking tests and this wire matches the specs to the limit of my pull tests.