I've seen enough charring on the cotton to suspect that it 'glazes' and forms a partial barrier to the evaporation of the fumes, and that's why I use a strip of carbon felt across the top of the cotton, which seems to work well.
I'm still trying to put my finger on why the Zippo's seem to be the worst of breed even after you replace the catalyst with proper platinum catalyst.
For the one experiment I did with the DE and the Zippo, I just thought that as it ran for 14 hours or so, most of the fuel must have been used. When the reservoir had the cotton, it seemed to go out and needed to be re-activated numerous times. With the DE, it did not go out once it was activated. Do you think it would be best to run the test again, but first weigh the DE, and then after the fuel seems to be used up, remove the DE afterward and compare weight to see how much fuel may have been left behind?
Good to hear that the CF hack makes sense. Seems odd to be preparing for forest fires when a virus is the big concern. But ironically I was listening to a podcast today that pointed out that the virus has caused much better air quality in polluted places like Wuhan which has cut deaths attributed to the poor air quality by 30%. And the air quality we had 2 years ago as a result of the fires was worse than they have in the worst city in China apparently. I can't make any home test kits for virus, but I can mitigate indoor air quality, so I may as well be pro-active now. (I'm just taping MERV 16 filters to floor fans to place in windows to draw outside air in, and also using the Negative Ionizers). I had them ready last summer, and we had no fire smoke to contend with, which is fine by me.