So changing my wick has stopped the popping. I think it was too tick.
I've recently changed to bamboo wicking from cotton (thank you, again, Raynman). Gone are all the issues related to having too much or too little or unevenness in building an "analog" wick.
http://www.e-cigarette-forum.com/forum/reos-mods/532694-how-i-wick-bamboo.html
Glad you found the solution. I have intermittent issues like that, too. I figured it was wick diameter problems as well (operator error is ALWAYS the case with the Reo, well mostly).
Papa, I REALLY have to try the Bamboo yarn. You all have convinced me. Enough satisfied Reonauts can't be wrong. I was concerned about Bamboo being a viable wicking material (Bamboo is "fancy" talk for rayon, which is essentially a synthetic fiber once the processing is done). But for $2 for a lifetime supply of it, well, I'll give it one shot. If anything, I can knit something with the rest of the spool should I not like it as a wick.
Would the same bamboo wick instructions work for organic cotton yarn? I have similar weight of cotton yarn as the bamboo, about 3 pounds of it for making doilies and dishcloths

. I might give that a go this weekend, and report back with my findings.