That much gauze on the bottom could be part of the post popping problem as well. You really just need a teeny bit (if any). You can also wrap the zonas tape all the way to the bottom of the post, and a little bit past the bottom, then pinch it so it folds over the end of the post and stick the gauze or bit of cotton right on that.
Also, when you back tape with the zonas tape do it nice and tight, it will help keep the post stiffer, and you don't have to worry about the wrinkles putting uneven pressure on the inside of the ear leather.
Be sure when you are making the posts that you follow greenkouki's directions. Back tape tightly--tape all the way to the bottom of the post--I don't use gauze--I use a very small piece of cotton that just covers the bottom to pad it a little--I tape that in place (actually I back tape it in place.
About tape--the tape doesn't have to be very sticky or 'strong'--in a way the tape is less important than 'how' you are using it. Zonas tape is low tack (not very sticky) breathable, fabric tape with a latex adhesive. The Johnson & Johnson Coach sports tape (which is nearly identical) is a more easily found in pharmacies and drug stores substitute for the Zonas. The all important taping at the very bottom is basically how you keep posts from popping out. And I use two or three short pieces to tape the very bottom--after the base is secure, yes, you don't keep angling the tape it just goes around the ear and post--laid on and not tight.
You don't want a lot of powder on the ear--you do want the tape to stick to both the inside and outside of the ear so just a thin layer of powder is all you need. I shake some powder on to my fingers and 'dust' it onto the ear and then kind of make sure I've dusted all the excess off.
You'll always lose a little hair but following the directions on the sticky about removing the tape will help a lot with not pulling out a bunch of hair along with the tape and old posts.
Good luck--hope this batch of posts stay in better.