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Are you using the coolshirt cooler (made by engels) or another cooler? I build my own by buying the engels cooler through another source and they have been great with the block ice. I know some guys use a cheaper cooler and don't have good luck keeping ice solid.
Mine is a complete FAST system. Maybe FAST coolers aren't as good as Coolsuit's. I should also say that I went with the smaller of FAST's coolers. Maybe I need the larger one. I have a friend with a Coolsuit set up so I'll borrow his and see if it works better. I have an RV with an added Engel Fridge/Freezer so I've got no problem bringing ice in whatever form works best but I still haven't figured out what that is.