I have much better luck if I torch the Kanthal wire first, giving it an oxidation layer. When I wound my coils with raw Kanthal, the ohms were always inconsistent; BTW I always make microcoil winds, one wind against the next. If untorched, the ohms would sometimes read lower than what I knew that length of wire would actually be, due to shorting between the wraps. When torched well, I found that consistency was achieved every time. Try torching the wire two or three times before wrapping to see if that helps.