Weird that you're not getting any shorts or anything. Is the resistance fluctuating on the mod? The only way I can see this sort of thing happening is a sporadic short, one of the wraps touching another loop and causing a hotspot or the negative/positive connection not being secured properly and the resistance jumping all over the place resulting in too much power going to the coil.
All of those things though, I'd assume you would be seeing issues on the chip or you'd get a real nasty dry hit before the wick separates.
Maybe try tightening the 510 to ensure the positive block isn't moving around...