Interesting... I have never heard of your problem before. But as far as i know, people have used 28awg on mechs without any problem.
Perhaps the wick and wire setup is too close to the deck? But if only the switch and bottom gets hot, or at least they get hot first of all, then there may be something wrong with the battery or/and some kind of resistance in the switch... Im no expert, just speculating.
Either way, good luck with it.
You know I thought it could actually be the battery but these things are brand new, I really dont know because I can't sit there and fire it and tinker with it cause it will definately start melting. TBH it's only the second time this has ever happened with the .28 gauge wire. I've gone through a ....load of coil/wick setups on my aga with .28 gauge just seems to fail or go out way too soon.
.32 gauge I can set those up first try they just seem to decline after about a couple days, the vapor production slowly goes down. The coil accumulates .... and gets nasty.
I have an RSST on the way we will see if it has the same problems, I could atleast eliminate the atty from the possible suspects then.