Hi Chris, first make sure that the traveler car without any line attached moves smoothly on the rod. I think that you are right in that your traveler line is too short. I would get a longer line and leave some excess at the end. My traveler line is fairly loose . Just tight enough so the main doesn't move under load . It doesn't have to be sta-set. I use hardware store line quarter inch.

Best Regards
Jeff Smith
www.http://JeffSmithPhoto.Net
732-236-1368