just wanted to hop on this thread since this is where the action it.

YES, I find fitting the wire between the washers a pain in the rear. I too have wrapped the wire around the top nut but lately I have just been using a pocket knife to separate the washers.
Also, I like aziffel found, have had to tighten up the top nut and apply more pressure and have noticed major diff in the way it heats. If they are loose, or not making good contact we are loosing some voltage transfer and thus not getting all battery power applied to the coil.
I too have tried the PTFE tape, etc around the wick to insulate it from the body but removed it every time as it hindered the wicking to the point I had to turn the device sideways to keep from getting dry hits.
I am in search of a PTFE tube that I can insert into the body like some of the other rebuildables have. Its very hard to tell if you are shorting to the body as there will not always be a "problem" per se', Other than it may seem like your battery is dead when you know its not. In which case you likely have a small wick to body short.
I absolutely love the Orion and despite the negatives that people post, It is in fact a direct battle between this and the "Zen". Not knocking the "Zen" but there have been many complaints about the button not firing correctly due to contact issues. We have no worries there at all
