Hey Chanelvaps - sounds like we both made some progress. Woot!
So some good news to report - I got the best build I've done yet tonight. It's not great, but it's getting there after applying a few of the pointers I got. First I started with Mac's link to Super's youtube video on a
tension wrap. I think the title implies this is now outdated, but it served me well as a starting point. This resulted in a much better coil. My first try, which I ended up keeping out of laziness, had some gaps that I worked around with a torch and squeeze. Again I suck at counting, but I think after backing out the starter wraps it ended up being an 11/10 wrap. This is what steam-engine worked out that I needed for a 1.6 ohm coil, and that's exactly where it landed.
The larger 2.0mm diameter allowed for more wick in the coil, and this was enough to fill the window without a 'flavor wick' jammed in. I think I understand why my last build sucked now. The extra wick on top was keeping the coil from getting hot enough. Cig's pointer on less cotton sunk in. Without that extra cotton in there the coil is burning nice and hot, and I'm blowing pretty impressive clouds with the AT. Finally!
There is still a lot of room for improvement, and tomorrow I'll rebuild the other AT with an eye toward trying to refine some of the rough points on this build. I definitely need to get something to spool the wire a bit better, but in the meantime the tape method is mostly working.
Question for you guys - are there any good posts or videos on how a pin vise is used, or which one is recommended? I found one that is focused on jewelry making and I think I get the idea, but I'm still trying to figure out how you guys are applying that to a coil wrap. Any pointers are most welcome!
Thanks again folks.