Hey Big D -
I'm liking the double wick ider you came up with myself. I just use my old fat wick E2's and cut the wick off each side of the old E2 cup and use both lengths without cutting them down any further. Have you found an advantage by snipping these double wicks down? I'm guessing you snip them approx. the same length of the original Stardust wick?
And lastly, what purpose does your last trick do by pushing down the silicone seal a little further?
BTW... I have a hell of a time getting that damn coil wire (negative?) to feed down along the side of the metal post and seal. Several times I get them back together and filled with juice before I notice the ground wire poking out a little where it got bunched up or worse where it pushed the last coil loop up away from the wick. Got any secrets?
I find that they wick better cut short. There is no bend for the juice to navigate. Just a straight shot to the coil. Although for a thin juice like 100%PG, I can see where it may be advantageous to keep them longer if you find it still too wet.
If you don't push the silicone ring down that makes the positive contact, it lays right up against, or very close to the coil. Burning silicone taste and blocked airway if that happens.
Know what you mean about that ground wire. Like shoving a noodle up a mules back side.
Wrapping stacked wicks is a pain. If you want to really get a headache, try tying in some no resistance wire for the contacts. I've made a couple like this so that the resistance wire begins on the wick. That eliminates the area of coil that is between the wick and the contact points. Makes it so there is no heated wire away from the wick.
One of these days, I'm going to put together a holder of some sort to make wrapping wicks easier. I'd love to see some idea's for this. My big ole fingers suck at wrapping lol.