I use my leatherman to twist the wires while I hold the 2 wires tightly with my left hand. I first grab the ends and twist, then use the leatherman to get a tighter grip. It takes practice. I get some really tiny twists, which really entails my wrapping the nickel around the kanthal. I use a large magnifying lighted stand which helps a LOT.
I can get a nice joined area of about 3mm. I use 32 Kanthal and 34 nickel which I like so much better than sterling, like you said, its slippery and breaks easy. I will try to take some photos. I dont know how I would go about doing a video , but will see if my son can help.
I cut my kanthal at 1.75" which is right at about 2.0-2.2, a little less I get about 1.8 and on depending on your liking.
I got this from the sticky in the rebuildable atomizer section:
At the temperatures we vape at, there should be no metallic vapors given off by these wires due to heat.
It has been stated by a number of ECF members that Kanthal (A-1) gives a cleaner tasting vape than Nichrome and that Kanthal (A-1) is a stronger more robust wire than Nichrome.
With either material, a thicker wire (smaller awg #) will, most likely, have a longer lifespan than a thinner wire.
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Resistance in Ohms/inch for the Resistance Wires
Kanthal Grade----- A-1 ------ A -------- D ----- Nichrome 60 -------- Nichrome 80
30 awg (Ω/in)----- 0.7 ------ 0.7 ------ 0.7 -------- 0.6 -------- -------- 0.5
31 awg (Ω/in)----- 0.9 ------ 0.9 ------ 0.8
32 awg (Ω/in)----- 1.2 ------ 1.1 ------ 1.1 -------- 0.9 -------- -------- 0.9
33 awg (Ω/in)----- 1.4 ------ 1.4 ------ 1.3
34 awg (Ω/in)----- 1.8 ------ 1.8 ------ 1.7 -------- 1.4 -------- -------- 1.4
35 awg (Ω/in)----- 2.3 ------ 2.2 ------ 2.1
36 awg (Ω/in)----- 2.9 ------ 2.8 ------ 2.7 -------- 2.3 -------- -------- 2.1
Spreadsheet calculations for the resistances
ETA: These ohms/inch numbers are a close average. Due to small variations in wiire thickness, if you cut a one inch piece of wire, the resistance may be +/- 0.1 or so ohms from the numbers in the table above.
Always measure the resistance of a new coil set-up with a multimeter before attaching it to your battery.