Salavat, again. Hi.
Just posting some updates.
I think I have it sorted.
Just to recap, I don't like faffing around to much and have decided to pursue a relatively simple res/ no res strategy; that being, only use silver on one leg - I don't have to calc to the mm yet there is only a tiny loss in resistence. And, when the silver is pulled up, it doesn't push the cup too far off centre, being thinner and softer. Or, if I wish and the ohms are ok for me, just res wire. I use mainly 30awg.
I've found that how the wick is placed/ rolled is my problem. 3 x 2mm silica stacked, with one leg silver, the rest 30awg (that for the post, silver pulled up) left me with no leaks after 3 days vaping. I tried to keep them 'stacked' and didn't wrap the wire to tight, thinking to allow for expansion. Filling the vertical channel, carefully without 'cutting' the silica as I pushed it down seems to have done the trick.
I think my problem before was wick style (eg. 6x1mm, or 2x2mm). The 6x1mm didn't wick as well as the above: pity, as I really don't like seeing the 2mm silica fibers splinter off as I screw the diver together. The 2x2 wasn't enough.3x2 worked.
Oh, some food for thought! Tonight, as now I really couldn't give a hoot about wastage, I joined silver/30awg wire (just one leg) and made a 'microcoil' with about 8 wraps. I wrapped it on a small screwdriver (@1.5mm), very tight and pulled some cotton through it. Trimmed it pretty short, about 1.5mm past the edge of the cup. Still the Diver in the Salt & Pepper tank on the dog (Vamo used like a tractor, for testing and stuff), @2.7ohms @ 10watts and its going great. I mean, not a drop/ hint of a leak.
Anyway, sorry to bore you, so good luck with things.