Just to follow up in case anyone else runs into this:
The above post was a fluke. I kept having leaks, and varied everything until I found the thing that got my leaks to near-zero consistently. I even bought some mouthguards and tried to boil them and bend them into this device LOL:
http://www.talkaboutsleep.com/message-b ... appliance/
It turns out the night I used two pieces of tape I ALSO slept on an incline (thanks to
https://www.youtube.com/watch?v=AdzKaB-ixxM to try to eliminate aerophagia symptoms).
This should be required reading for everyone on CPAP or dealing with CPAP issues:
http://www.tylervigen.com/spurious-correlations /
http://www.stats.org/causation-vs-correlation/
Sleeping on an incline is the only thing that worked to eliminate my mouth leaks. The incline needs to be pretty steep - I have a rolled up blanket and two pillows that I sleep on, at an angle of 20-45 degrees.
The mechanism seems to be that my tongue / palate collapses when I sleep, and this makes me choke and wakes me up (subconsciously).
Then my jaw drops because I need to mouth breathe, and voilà: leaks. I mean, how else could air get in if my tongue is blocking my throat? Pretty scary because I also have tape over my mouth every night.
-appo