Point taken about 'practicalities'.
I'm no scientist just a very old engineer. if the wire was just solid alloy as you think, without any insulation, when you push the coils together the path of least resistance is not through the coil but but across it, basically a dead short. So therefore the outside of the wire has to have some sort of insulating properties. I wasn't being technical just curious. Anyway I phoned Kanthal and got my curiosity satisfied.
I'm after designing a mod as I got too much time on my hands and there seem to be a few problems such as dry hits, flooding and the +ve battery contact burying themselves in the rubber insulator etc. I've read a lot about, not to mention the inherent weakness of the 510 thread. Compare this to the Mister (
MISTer -hybrid (Silver plated contacts) | VJ-Mods) where the thread on the atty base is M20x1 and screws directly into the tube seems as good as it gets for strength.
After that there's an idea I had put into my head about the atty being variable temperature control and porous ceramic tube wicks, but there's along way to go with that. But I'm sure it's doable in the future along with fluid supply controlled by the vacuum from inhaling.
For now I think I'll just stick to the body design and leave the rest to the eggheads.
Thanks for you reply though.