Scary!
I may be wrong, but I'm pretty sure the way you are putting your QR back together is wrong.
First step, read the manual-
http://media.bestkiteboarding.com/manuals/08_BEST_BAR_manual.pdf
I think the spectra loop goes over the metal loop, then the pin goes over the spectra, through the metal, then into the webbing sheath. There's a close up on this thread here-
forum.bestkiteboarding.com/viewtopic.php?t=8066&sid=b792ad864bc85db6c85e83d024489484

Check your QR's people. Make sure you know how they work and how to put them together. It'd be good to see more "kook proof" QR's from manufacturers that can't be reassembled incorrectly.

wow. ****. I'm an idiot. Thanks for that. You were totally right. (fixed very cheap). To make myself feel slightly less stupid I'm convincing myself that I got it that way second hand and have just been putting it back together how I found it.. Either way thanks for pointing out such a stupid and potentially very dangerous mistake.

Do yourselves a favour guys, and upgrade those old style releases for a real quick release, what you are using isnt safe , they tighten up under load, and you have to be superman to pull the pin if your in trouble.