It was a crazy weekend so I wasn't able to experiment as much as I had hoped, however I did try straight VG thinned with distilled water (no flavour added) and low and behold ... no coughing!!
OK so next step ... I'm going to try straight PG and see what happens there. I think jmpublius may be right ... I think it might be the nicotine ... grrrr!!!
So once I try the PG I thing the next step will be to introduce nicotine slowly back in to the mix
Thank you for all the suggestions everyone ... Nana, let's kick some analog ....!!!