@Silver, as discussed... please find below my build process:Oh no, sorry about the BB trouble @Silver.
I have some pics and tips for you if you have time to try it out?
I start with a 2.5mm ID coil:
I wick it as tight as I can without deforming the coil.
I cut the cotton at a length of about 15mm (give or take, doesn't really matter).
I then flick the cotton back and forth with my index finger, fluffing it up nicely.
No combing or anything, just flicking. This forms a nice fluffy bowtie:
I carefully cap the Exocet, making sure not to pinch the cotton.
I then cut the cotton very close to the cap, about 1-2mm:
I then blow on the tails a couple of times. It puffs out and fills up the gaps properly.
From there its a matter of putting it back in the Boro, making sure all the orings are lubed and filling it up.
I install it at a slight angle so that when I tighten it down it straightens up as it always turns a bit:
This has worked very reliably for me ... and I have to thank @Amir for teaching me how to properly build the Exocet. All credit goes to The Man