What kind of line are you using? I recommend something like New England Ropes Sta-set 3/8". There is some twist but nothing really objectionable

That sounds about right. Its beeen so long since we set it up that I'm not sure. We stole the idea from Pendragon three (one ton Davidson) that one of my crew owns and we did 2000 Vic-Maui.Twist has never been a problem and the price was a lot better.

Two years later we are still using the gross/fine system similar to Rhapsody's in post #3867 on page 2. This only required one new block as shown in the attached picture:

H196 Low Profile Triple Ratchet/150 Cam-Matic/becket (new replaces the H004)

It's possible you can still get the H196 at http://www.apsltd.com/c-508-ratchetsautoratchets.aspx and save yourself drilling pins.

Standard J/30 triple stays on the boom which provides flexibility in switching between 4:1/4:1 and 6:1/2:1. The triple does not swivel which means tangles only occur at the base. I had the same twisting problems as Mango when testing a swiveling block. Usually crew trims main, so both gross and fine blocks face forward with sheets in front of the traveler. If helm is trimming main, blocks and sheets go aft. Changing from one to the other takes unshackling the boom block and rotating it 180 degrees and is best done at the dock.

I've had a Ronstan Cam Cleat Swivel Arm Base in my tool bin for several years and have wanted to try it out on the H170 Hexa-Cat Base of the gross trim. Space constraints with the trimmers means that it would probably have to face aft while the crew prefer it forward.

The 4:1/4:1 works best in winds under 15 knots. I prefer 6:1/2:1 for heavy air, reeving two more parts of the gross sheet and replacing fine tune's floating double with a single. This is how it is usually left during the heart of the summer since most of our racing is weeknight beer cans when there is little time to fiddle around with gear and thunderstorms are often predicted.

Unlike Rhapsody I keep both ratchets on all the time. Fine tune is long enough to be adjusted by the helm or crew from the rail upwind. Our system has a stopper ball at the junction of the gross tune sheet and whichever floating block is being used.

Problem is, due to the twist (guessing), my lower original block has the wall worn from line chaffing the side at an angle. As a result, the line jumps off the sheave, gets hung up in the groove, and locks the whole sheet up. Top triple is showing signs of wear as well.
Solution is new blocks. Thats why I'm asking for a "optimal" system. Technology advances, maybe there are better blocks for this setup.

This is what I'm looking for! I understand the "one continous line" theory now.

http://www.ronstan.com/marine/product.asp?ProdNo=RF72700

This is the cheapest Harken version. I just dislike the cheek side walls of harken's "classic" style blocks.

http://www.marinerparts.com/3-3-1-6-1-gross-tune-fine-tune-system-harken.html

If it blows in Hawaii like I think it does, you probably want at least the 4:1/8:1 and it's only a bit more expensive:
http://www.marinerparts.com/4-1-8-1-gross-trim-fine-tune-system.html

Also a fan of the 'standup toggle' if you have a Harken traveler.
http://www.marinerparts.com/midrange-stand-up-toggle-w-control-tangs.html

Thanks Bob. I was actually contemplating the higher purchase system and didn't know if it was overkill or not. I went out yesterday with the wife and it was blowing stink. I actually solved my problem by replacing the line. It seems PO had 7/16 and blocks call for 3/8 max. Now blocks run smooth and with the addition of a swivel snap shackle attached to top block and boom bail, the line doesn't twist.

I figured this out too late because I ordered the 4:1/8:1 system, in your post, the night before. O well, just another old hardware upgrade. I can always use the old blocks for my boom vang since I snapped that block last month. Old parts are old and break.

Is there anyone who eases main sheet vice travel down in a puff? It was too hard to do with my old main however I don't have windward sheeting traveler yet and I'm wondering if this is a viable alternate? (Easing fine tune vice travelling down/up). This would save me alot of time and money.

If you don't a decent traveler system the alternative is to vang-sheet, vang on and ease mainsheet in the puffs.