Hey, cigatron. Thanks for chiming in. I built one of your coil winders, except that I used doweling as opposed to square stock. It's what I had lying in the shop. It works great! I'll get around to posting some pics of my coiling escapades eventually, if only to encourage other noobs in the process.
You raise a good point. The scientist in me always asks the question "why?". I've been building resistance coils and simple motors since freshman year in high school; electronics shop. Over the last 20 years, I have built hundreds of electronic "gadgets" for use mostly as props and special effect in the entertainment industry. When I started my vaping journey, I was no stranger to Ohm's Law, PG or VG (we use these liquids for smoke, fog & haze effects).
Mac's T.M.C. technique/theory is solidly grounded in physics and does everything he says it does. You'll get no arguments from me. I do ask whether it's always appropriate for our use, however, depending on the application. Admittedly, I have not had extra time over the past three months of vaping to carry out many experiments of my own. The 200+ hours combing through threads here took up most of my free time (and sleep as well). Even Aspire's new, much lauded, Bottom Vertical Coil is a helical, non-contact coil. What do the manufacturers' engineers know that we don't? T.M.C.s could just as easily be wound by an automated system before installing in the heads.
I rebuilt my first few KPT2 heads using Rip's method. Then I found this thread. The contact coil is certainly more efficient than a loose hand wind over silica. When I nailed my first T.M.C. in the KPT2, it was a noticeable difference. It was much more efficient, raising resistance, outperforming lesser coils with less voltage and creating much less ancillary heat (KPT2/EVOD base and 510 connections were noticeably cooler). If T.M.C.s are far superior to helicals, however, why don't the better manufacturers use them?
Here in the vaping community, we discuss Ohms, Volts, Watts, Amps and coil winding techniques. What we really need to know and discuss is BTUs or joules; heat: how it's created and transferred to the e-liquid for atomization. It seems that our goal should not necessarily be electrical efficiency but thermal efficiency; two different things.
This is probably not the appropriate thread to undertake such a theoretical/conceptual discussion. But I'd certainly like to start that discussion...