I like the sound of all this, but i'm slightly concerned about exposure to silica and developing Silicosis, which is very serious. I don't know if there is any risk of that with silica rope.
I doubt it. What causes Silicosis? According to Wikipedia, it's caused by inhaling silica dust. It doesn't seem likely that silica dust would be released from silica rope, as the fibers cut cleanly. It's certainly no more dangerous than fiberglass, which can also cause a form of Pneumoconiosis if it become airborne. Really, I would say there's less danger of inhaling silica than there would be inhaling microscopic bits of a cigarette filter, as cigarettes are neither wet nor have to endure a twisty, turny (also wet) path to get from their origin to your lungs.
The probability of inhaling wick fibers is infinitesimal. When you're twisting a wick up, you will snip the fraying ends off after inserting the wick, ending up with a Darwin-ish bunch of the fittest fibers in your PV. Even if not, if you are sloppy and leave a few fibers sticking out of the twists, these fibers will still be pretty much glued to whatever they contact first by your juice, unable to become airborne.
The probability of burnt / decomposed fibers is even slimmer, since the point of volatility of silica is about 2300°F. I think your coil will burn out before the silica does.
There's a good chance your atomizers already use silica inside the twists of the coil. From what I've read and observed, I'm pretty sure that's what's in OEM Joye eGo-T attys anyway -- not just the wick, but the coil as well.
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