ETA2: As I recall it, people started switching to cotton when rebuilding became popular. It was a pain to wind a coil around silica rope--we had to stick a needle through the rope to stabilize it first. I hated that process and never could get it quite right. With cotton, you made a coil first (toothpicks and skinny drill bits were handy) and then just cut the wick to fit the coil. We started with organic cotton balls from Walgreens.
Never could get that quite right either. And I had an even worse time with those Evod//T3/pro-tank-II style "non-rebuildable" modules that people would rebuild... I don't think I ever got a single one of those right, come to think of it. They would either leak or dry-hit. Well... They often did that anyways brand-new -- just that rebuilding them led to it being
always.
ETA1: I wonder if the wicking wasn't so good because the fibers were twisted into ropes. This may have impeded wicking. Hmm... I might go and find some old silica ropes and try to untwist them.

Maybe not.
If you want, I could send you ~130ft of Fastech's 2mm silica with which you can carry out these important experimental endeavers!
Please? For scientific purposes?? Anyone???
But silica never burns.
This and my surplus is why I developed a technique to re-wick silica in-place. I use it from time-to-time in drippers. I once tried a combo rayon-tufts/silica wick in a Kayfun 5 tank (so I could just dry-burn), and was more successful than I thought I was going to be, but I kinda gave up on that for now.
I don't really think silica wicking is as bad as we used to remember it with those old-style tanks. My main drippers I used back then were those 'octopus' type with multiple strands - and those were mostly fine - that is, until I needed to re-wick (aka recoil) myself.

So that multiple-strand thing carried over to my more modern in-place technique.
But I do have to wonder: just how much of my 3lb/900ft box of rayon will I be stranded with when something better comes along?
