Well, there are actually two methods I use to build them. The first is for a single coil build: I simply use some 32g Kanthal and wrap it around a plastic zip-tie to give it an oblong shape. Of course, I use Steam Engine to tell me how many wraps I need (usually between 6-8 for a 2.0 ohm coil). The rest of the process is best explained in video - I would record one myself, but I haven't really got a camera. Though thanks to the wonders of YouTube, somebody has already made a video using this method. This was the way I built my first ever coil, and it worked the first time I did it - super easy!
The 2nd method I use is for creating dual micro-coils and I actually discovered it by taking one of the factory coils apart and observing how they did it. Again using 32g Kanthal, I wrap the wire around a 1/16" drill bit about 15 times (I've also used an 8/32" bit which may work better). Do this twice to come up with 2 micro coils that are identical and individually provide 4 ohms of resistance (when combined, they are halved to 2 ohms total). I then put the cotton wick in the coils before placing them in the housing. When stacking the coils, I take the legs of the top-most coil and run it through the cotton that's in the bottom coil to keep them both in place and prevent cross-over (manufacture's method). Putting the cotton in the coil before trying to put the coil in the housing gives you a lot more control over the coil to ensure it doesn't twist while you're setting the legs. The rest is...well, the same as the first method - run all 4 legs through the bottom, 2 on the inside of the rubber gasket and 2 on the outside. Slide the center pin in, trim off the excess, put the top back on and test it.
A few tips for building coils:
- ALWAYS check your coils before using them! You need a resistance meter of some sort - if you don't have one, don't try to build coils.
- Heat the Kanthal wire to red/white hot before wrapping it with a torch or zippo lighter. This will eliminate the spring-like properties of the wire making it much easier to work with.
- You can build a single coil with 28g wire; however, this is not recommended as it will quickly damage the rubber insulator used in the coil. 34-36g wire is the factory standard for this dual micro-coil.
- When setting the legs, make sure that no part of either coil is touching the side of the metal housing. This will cause a short and the coil will not work properly.
- If you're new to building coils, try making a single coil first. It's super easy and will get you familiar with how these things work. Also don't worry about the performance. A hand-made single coil in this tank is just as good as the factory-made dual coils - if not better!
- Be prepared to be patient! I have very shaky hands and usually can't work with small wires. But after taking my time and building a few, I can now make my own coils is just a few minutes.
Anyway, hope that all helps you out. Just keep in mind, building a dual coil is at least 10x harder than a single coil - but that still doesn't make it impossible. Practice really does make perfect coils. Good luck!
