My latest experiment was 30 awg 80/20 nichrome, 5 wraps (viewed from any angle, except where the post is, which would be 6). I'm using 635 SS rolled tightly. It has a bit of clearance in the 2mm-ish hole in my DUDs. I haven't measured resistance after I used/seasoned it, probably in the 1.3ohm range. I can not make it short, even with loose/frayed ends (those who have used 635 will realize there's no getting around these).
I'm running 3.4v right now, which is 8.9 watts. I'm loving this setup, as even my Rawr antidote (blueberry/lemonade) is strong in flavor, and you can chain vape all day without a dry hit. Some of my other coils would lack flavor or taste burned. I'm happy with the coil count since I have been unable to even intentionally induce a short by pulling the wick in and out of the coil, and even scoring it with a knife. I also don't get a lackluster first pull, as I've got enough wattage to start atomizing quickly.
One thing I learned - when coiling your wire, pull the wick in to almost touching at the positive/center post. Wrap the wire opposite the direction the screw/bolt tightens on the center post. When you tighten it, it will very slightly push out, but you'll have a very short wire path before it coils around the wick. You'll avoid a major hot-spot problem many have with the wire being too long before hitting the wick. Also, with lower gauge wire, you can wrap a bit tighter around the wick (not pinching it, but resting against it all the way around) which avoids the pitfall of a lack of flavor and/or burned fluid. studiovap's wonderful pictures illustrate what 'just right' means when it comes to coil tightness against the wick. Touching, but not deforming the wick.
I've also started spreading my coil out a bit more across the wick, but still nearer to the air hole in the side of the top casing. I would get dry hits or weakly flavored hits when I spread the coil across the whole range of the wick. Having a coil wrap over more area of the wick, but concentrated where the air would be drawing made that problem go away.
I'm now at 100mm of 635 in a 2mm wick hole, with room to spare around it. The only gotcha is you need to (before it's broken in) put a few drops of liquid on the top of the wick and burn a bit to get the wicking started. Once it's going, you can empty out the tank and fill another fluid without dripping on the top of the wick, and it'll wick like nobody's business. I'm hand rolling the wick until tight, then putting it between two solid but textured surfaces, and rolling it in the same (tightening) direction 5-10 times to get these solid core wicks. You can run it a few times in the opposite direction after to loosen it up just slightly, and get that solid yet springy wick studiovap has mentioned. I've had great success with this when dealing with 100% VG liquid that I used to get no flavor from/dry pulls.
Regarding wick sizing, there doesn't seem to be a huge difference between the 100mm and 80mm wicks I have running into two of my DUDs. I think I've hit a point of diminishing returns and am now wasting excess wick. You'll know when you get to that point when you encounter no dry pulls. Beyond that stage, having even more fluid as a buffer is pointless. With how expensive 635 is, I'm considering stepping down.
One last note, I'm using a cheap $18 ego-t 18650 mod. I'm running regulated, which is 3.3-3.4v (with my batteries, under load, is generally 3.4v). No mechanical mod is necessary. I'm using cheap DUDs, and studiovap is using much better quality units with much larger wick holes. He can run higher wattage output with less coils and get good output. I run lower wattage with more coils (and higher ohms), but am having good luck. Without comparing A/B it's hard to know how much better his setup is, but my point is having a regulated/lower wattage output device than a mechanical mod doesn't mean you can't use this style of atomizer. I'm definitely far ahead of a Vivi Nova at this point.