Hey Bill, I know you must have tried everything you could but if I may make another suggestion. I've used Kayfuns for a pretty long time now and have found that if the coil or legs of the coil is too low or if the wick touches the air hole it leaks. I usually keep the coil raised 1-2 mm off the air hole and keep it at a slant. This way I can wick in an S shape, the legs of the wick go along the two sides of the base forming an S.
sand,
Height and clearance of my coils are good.