I'm currently using claptons in my X's too. I've successfully used 2mm - 3mm ID's in the X. Kanthal + ss316L.
Maybe try not combing your cotton bacon and see your results??? You might be surprised with the result and that may work better for you. There is no hard and fast rule that says you must comb. From what you said, perhaps you are combing way too much. It comes down to whatever you find works best for you. Experiment and you will find that happy place.
I would try your wick a tad longer than where you are trimming.
Sorry, I don't know what kind of cotton Todd uses.
My wicks last ~14 days (cotton) and ~30 days for rayon (Tidi or Graham's/Sally's).
I do not comb the Tidi rayon wicks. Tidi is much finer than Graham's/Sally's. Trim and tuck.
For cotton I use Cottonmans Mavaton's Select (oils removed) and Carolina Blend 200mm (oils removed). He is a cotton farmer and seriously knows his cotton. It is not cheap but it is the silkiest/finest and cleanest cotton I know of. It lasts and wicks great with all build types. I've used his cotton for years because I was very unhappy with the performance of all the rest. And I tried most. I never comb Cottonman cotton. Again, trim and tuck.
In one of my X's I have a 7 wrap 0.70Ω 2.5id 32*3/40 twisted fused clapton, nearly the same as you.
I have a question ... after you fill your Project X are you opening the JFC all the way? I'm sure you are but the thought crossed my mind. Sorry.
If you are not opening it all the way that will give you dry hits.
The two "flat" sides of the Project X tank should be centered with the long vertical line for fully open. Like so...
View attachment 834053
After I build/wick or refill I don't let mine sit for any time because my wick is already saturated from priming and ready to vape. When I prime my wicks I don't go sparingly with juice but I also don't go heavy. Just enough to saturate the "entire" wick.
More wicking thoughts ... If your wick is "too" tight in the coil you will get dry hits. If it is too loose it will flood. With cotton when you insert your wick you should feel some resistance moving it side to side. Not too much. If it is moving your coil a lot or distorting its shape then that is too much. If you see the coil move a little that is fine. With the wire you are using the coil will move more than say with 28g kanthal or ss316L.
Hope that helps.
Dupli photos: You can always go back and edit your post to delete the duplicate photo's. I've done that more than once myself.