Just wanted to update you guys. I tried one last build, and I think I got it to work. Build is same as before, 1.4 ohm, 28g kanthal, 9 wraps on a 2.34mm drill bit and organic cotton wick cut short. When I went in there, the post on the right (fill hole facing towards me) was a little loose again. This time, before building, I cleaned it really well again, then took some compressed air and blew it out really well. Not sure, but it seemed like that post seated a little better than before. Now it seems to be vaping well. So I'm wondering if a little piece of metal left over from the machining was under there? Whatever it was, it seems better now.
I'll take it with me today, along with a backup, and see how she does. Will let you know.
Thanks again for all the help troubleshooting guys!