I was reading your frustration with the BFD method and there must be something going on that hasn't been addressed (except for the exchanging it for a new replacement!). I have been using the BFD in both the short and mega carts with fantastic success. My carts go dry, no mouthful of liquid, and strong vapor. This may sound stupid (sorry) but do you hear "gurgling" when you press the battery switch and hold the mouth piece close to your ear. The first time I used my Tornado I heard it and was concerned. It made sense to have the noise, I had just never heard it before. I would think that if you don't, your atomizer is not heating properly which would certainly account for your issues.
As for contacting TW with your issue, you should not, IMO, feel conspicuous as that is why you deal with a particular vendor. And if they make you feel uncomfortable, don't patronize them. They should bend over backwards to assist as for one: you purchased from them and for two: there is a lot of competition out there, and you can go elsewhere. They should help you make it right or replace/refund. I, for one, have been extremely satisfied with my Tornado and with their service (they replied quickly when I had a question). Don't give up and Good luck. Allan