The cotton is organic. I've never boiled cotton to rebuild my wife's aerotank coils and they've done fine. This thing's just a completely different animal. The juice channels seem to be fine. The cotton is a bit dark under the coil after just a few minutes of vaping, but not black. The vapor is also tearing up my throat. I coughed for hours last night and had trouble breathing. The juice I'm using is the same stuff in my wife's tank, so I know it's not an issue. The whistling is irritating too.
Umm....something is definitely wrong then.
First off, the vapor shouldn't be harsh. Secondly, the cotton shouldn't be discolored after a few minutes at all.
I think you said you've tried different coils/builds....but I would say try again. It honestly looks to me like the coil is wrapped too tightly, or you need to make the wick thinner.
I've found the kayfun to be optimal in the 1.1-1.6 ohm range..... so you should be fine in that department. You never mentioned what voltage/wattage you are trying. You are using aprovari, so I guess you aren't adjusting the wattage. What voltage are you at?
If you lower the voltage as low as it can go, and you are still getting a burnt taste, something is DEFINITELY not functioning properly. Either the coil isn't really 1.7ohms, or the wick is too thick, or the coil isn't hitting properly.
I recommend:
1. Re-check the ohms. Make sure it is indeed 1.7ohms.
2. Take the cotton out, and dry burn the coil. The coil should be turning red from the center FIRST, then spreading outward if its a micro coil (that looks like what you built) If it isn't then it means you need to rebuild the coil, or fix it so it heats up evenly.