Thanks for the help guys. I will check his line lengths (and mine) next time we're out, probably tomorrow. It's something I'm always meaning to do but it always seems to be tomorrow. I think I just get pumped up by the time I've run out my lines, thinking about getting on the water.
My friend had figured out to rig a small leader off the loop in the trim rope. It makes rigging the pin much easier as well as getting it thru the cuff. So he's happy to use it now.

Bondo that wasn't us, we were at Brighton and my friend has the red/orange/black colours. Bit of a co-incidence that you saw some guys having the same problem!
Have a look at the hole in todays brighton wind graph..
http://members.optushome.com.au/sataskov/Weather/kbb.htmWe had just arrived, one of us measured 14-16 knots. My friend with the fuel put his arms out and said 'I wish there was just a little less wind' You guessed it, next thing there was nothing but raindrops. When the rain stopped there was just nothing. It came right just as suddenly half an hour later and we had a great day. So be careful what you wish for guys!