I (as an improviser/maker of many things/professional level electronics solderer and jeweller) too am good with handling small objects as well. I also have lots of patience and a never say die persistence, but I was at it for weeks with my CHID with no luck at all. I actually went clinically insane('r') several times.
In the end when I got my 2nd CHID, I just got it to work - seems I just was not heating the wick near enough to get a good resistance layer on the surface, nor for it to wrap tight easily
- I cut a long strip of 500 mesh the right width plus a bit, then I heated the whole sheet on the stove until it glowed, and allowed it to cool fairly slowly.
I used a pin to get the first edge to curl back on itself, then removed the pin and rolled the wick up quite tight - checked thickness for good fit into the wick hole (ended up cutting a strip or three off the end) - nice tight fit - just able to push it in.
Next I unwrapped the wick with the aim of next wrapping it starting at the outer edge/other way in - the edge that was to be at the surface (the one that some folks fold), well I heated the hell ot of that and knocked off any glowing strands that wouldn't burn away - found this better for me than folding - the double-thickness ridge the fold produces was giving me coil-to-wick shorts.
Once that was done I heated the whole mesh again and let it cool slowly to re-anneal it, then rolled it again but starting from the outer edge of the mesh (used a pin to get that first curve again), but this time I rolled it *solid* tight, so it would almost just drop into the wick hole only just touching the sides.
I then heated the entire length of the wick until it glowed orange, and plunged under a running tap. Rolled it between my fingers again, chose the coil end, and heated that orange, then under cold tap, 3 more times (speed up drying out time between 'burns' by sucking or blowing the water from the wick).
The wick is now rigid but not brittle at all. I put it into the wick hole, removed atty centre nuts and post, and cut a section of (29 guage but it doesn't matter) kanthal, and gave it a gentle curve by pulling it between my thumb and a smooth drill bit.
I heated the kanthal gently over my stove until it glowed, then *slowly* raised it from the heat to cool (to anneal it needs to cool *slowly* - sudden cooling causes the molecules to crystalise in a hard form).
With the wick in the atty, but centre post etc. removed, I put one end of the kanthal under the ground/-ve screw, then wrapped the wire in the drection of the curve I'd given it, around the wick, *by turning the atty*, and not by moving the wire around the wick.
At the top of the wick I gave the kanthal one extra wrap, then used my thumb to hold the end against the wick to stop the coils loosening.
I put the centre pin and bottom 2 nuts back in place, pulled the end of the kanthal tight, undid last/extra wrap, then wrapped it round the cenrte post (I do it in the reverse direction/counter clockwise), put on the top nut and tightened against the wire - you can tighten it from the 2nd nut down 'upwards' as well as top nut downwards to avoid pulling the wire too much.
Gave the bottom and top of the wire a slight 'kink' as as been suggested in this thread, then dry-fired - all coils eventually glowed with *no* shorts from the outset, and I wrapped that coil *tight* - in fact it left tiny but visible indents in the mesh surface but no short issues at all, even on 5 volts with a 1.7-ish ohm coil.
Since this I've rebuilt my first CHID the same way and a new AGA-T with the same success, first time, and it only took me about 1/2 hour max each time.
If ya can make sense of what I wrote, I hope it helps - don't need any more insane people do we ',;~}~
DV!