I don't find cotton to be at all difficult to keep wet. I use a mini vivi nova most of the time, using short wicks that don't hang into the juice, and just make sure to tilt it enough to wet the wicks every few hits. I rebuild them after about a week, and rarely find any loss of fiber at the coil. Sometimes it seems slightly singed on the outer threads, but not significantly.
I currently use Aunt Lydia's bamboo crochet thread, and find it to be a bit more resilient than cotton. Hemp string would probably be even better, but I've not tried it.
Personally, I wouldn't call the fumes from burning cotton 'noxious'. Processed cotton should be around 99% cellulose, which generally produces carbon dioxide, water, and very little particulate when burned. I'd imagine that there would be traces of other chemicals, but we're talking about a minute amount of material over a fairly long time, if it gets burnt at all.
I do a burn test on all of the organic wick materials that I've used, just to try and make sure that they aren't mixing in synthetic fibers. Cellulose-based fibers should burn with a nice yellow-orange flame, with little ash left behind, and smell slightly of burning paper. I burned a clump of cotton balls once, out of curiosity, and it was barely noticeable in the air.
this is great to know. the way the ecf member warned about the burning cotton was scary. i wish i could find the post. the member had a specific chamical name that was produced. and it was presented as a fact, rather than just someone saying it tasted bad. but for nobody to have recognized it by now, must have been my perception of the post rather than actual fact.