I've had the very same experience with mine and a 3mm build. With 3mm coils I had my wick (KGD) Very Tight, with 3.5mm coils my wick was Snug, and with 4mm coils I had just enough in there so that my coil would not be Popping all the time. Popping is different than Crackling, Crackling is OK, Popping is a sign of either not enough wicking material, or, pumping too much power to the coil for the build that you have made, IMO, and this I have found to be true with my Siren's.
Your Welcome kydo, glad I could help you out, if even just a little. I have been asking myself that very same question, "Why didn't I try a bigger coil way back in the beginning" ?? Sure would have saved me a lot of work, time, frustration, and juice.
Be advised though kydo, that you will get some condensation at some point, even with the 3.5mm and 4mm coils. With my Siren 25mm tanks and the see-thru glass deck tubes, I have watched the vapor first rise (as you vape watching in the mirror), then fall back down into the air tube and disappear under the coil (when your done with your vape) after a tank or two, and at some point your air flow ring will get damp (but not wet like before), but take a Kleenex or damp cloth, and just wipe the air flow ring off. It's still a lot less mess than before though, and really no big deal. Sometimes I'll take a Kleenex and twist one end, stick it into the biggest air hole on the air ring and swab it out to get the built up condensation mopped up (there really isn't much), but that's only after about the 5th or so tank full, and I'm a very fastidious vaper, as far as cleanliness goes. My wife says that I'm "....".
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