Could I maybe test it on my ohms reader before I cut the leads to see if it's because I'm tightening them too much? that's the only thing I can think of, I just want a single coil to start out with, I have 22g, 24g, and 26g A1 Kanthal. What mm should I use and how many wraps of which GA should I use for a single coil with a reading anywhere from .3 to m5 ohms?
Sounds like something is Funky. So here is what I would do.
If my Goal is to be at a Dual Coil with .4 Ohms, then I need to make 2 Coils that Each have .8 Ohms.
After giving my RDA a Good Cleaning, I would make a .8 Ohms coil out of 26ga Kanthal A1. Wrap 6 Wraps of the 26ga around a 2.5mm Screwdriver or Drill Bit. Don't worry about Half Wraps. And don't cut the Legs yet.
Now I would put the Coil in you RDA using the Outside Right Hand Post and the Center Left Hand Post. Don't cut the Legs flush with the Posts yet. Just let them stick out of the back of the Posts but make sure the are Not Touching anything. Things should look like this...
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Now tight the Post Screws until they are Snug. Give the Coil a little Tug to see if legs can move in the posts. If it Can't, double check that the wire sticking out of the back of the Posts Isn't Touching anything. And then screw the RDA Base on you mod and give it a Brief Test Fire. The Ohms should be around .8 Ohms. Doesn't matter if it Isn't Exactly .8 Ohms. But it should be Close. Like .7 ~ .9 Ohms or so.
Now unscrew the RDA base from you Mod and Remove the Coil remembering which holes the legs were in. Then Put the Coil in the Other Post Holes.
It should look like this... | 0 | 0
Do the Same thing as before. Tighten the wires Snugly and Test on your Mod. You should get the Same (Basically) Ohms as the 1st Time. Around .8 Ohms. Now you know that Both Sets of Posts Works. And both give you the Same Ohms with the Same Coil.
Now you can Trim the Wires sticking out of the Back of the Posts and Build a Second Coil that is the Same Ohms as the First Coil, .8 Ohms. When you put the Second Coil on, it should look like this... | * | *
And when you Now Test it on your Mod, it should Read .4 Ohms.
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If the Above is just Too Much to do Right Now, and you just want to Run a .4 Ohm Single Coil, then you could make a Single Coil out of 24ga wrapped 5 Times around a 2.5mm Screwdriver or Drill Bit.
Just make sure to use one of the Outside Posts, and then One of the Center Posts.
Hope this gets you going.