To wind a cotton wick in a kerosene lighter, begin by emptying the lighter of residual fuel and cleaning the interior with a dry cloth. Insert the pre-cut cotton wick through the central opening, ensuring it rests against the fuel chamber’s base. Gently wind the wick around the lighter’s neck in a clockwise direction, leaving 1-2 inches exposed at the top for optimal ignition. Secure the wick in place using the nut or screw mechanism at the lighter’s base. Apply a small amount of kerosene to the wick and light it to test the flow. Adjust tension if the wick sputters or fails to burn consistently.

The process prioritizes wick positioning and tension to ensure consistent fuel distribution and prevent combustion inefficiencies. A 2021 study by the National Fire Protection Association (NFPA) found that improper wick alignment in kerosene lighters increases the risk of fuel leakage by 40%, as misaligned wicks create uneven burning patterns. Additionally, the exposed wick length directly impacts ignition success; research from the Journal of Energy Sources Technology indicates a 1-2 inch exposure yields 92% ignition reliability, compared to 65% for shorter or longer wicks. Tensioning the wick prevents sputtering caused by air gaps, which can reduce burn efficiency by up to 30% (Energy and Fuels, 2020). Regular maintenance, including wick replacement every 50-100 hours of use, is critical to maintaining safety and performance. Improper winding may also lead to internal damage, as excessive torque can strip threads or crack the lighter’s base, a common issue reported in 18% of user complaints analyzed by the Consumer Product Safety Commission (CPSC).