I understand your frustration...The desire to assist is appreciated. I tore down the build, and have cleaned and stored the KF5 already, so I can't get pics.
As far as coil & wick, I've been using 28awg SS316L and rayon for some time now, in TC mode, at 30w/450°F, spaced coils. These settings work best for me with this liquid.
I've tried coil ID's from 1.5mm to 3mm, really dense wick, really light wick, and lots of variations in between. I've paid special attention to wick tail density and length, as well as just packed it full. As I stated before, I had the best luck with really thin wick tails that just tickle the deck, but it was such a pain for me to deal with, it's a non-starter. I've tried pretty much the full gambit of things.
I learned a hard lesson about filling level early on with KF5, as in if it's overfilled, it will flat out purge liquid not just weep. That ticked me off, but I got by that.
I really do believe it's a liquid issue. I had really good luck vaping a high VG liquid, but that's just not something I can do even most of the time (unlike most folks). I'm a strange vaper. I accepted that a long time ago
What's really important to me is being able to reliably build an atty every week or two, fill it once per day, and just vape it. Regularly having to deal with leaks, or tinkering with coils, worrying about whether or not a moderate change in temperature/humidity is going to cause an issue, having to constantly open & close JFC to make sure leaks don't happen...not enough time in my day to deal with that kind of stuff.
But, I simply must know... Did you tighten the 5mm nut on the bottom that holds the positive screw?
I found that was a wee bit looser than I liked on mine.
Jim