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We have two of the now earlier Mustang Lil Legend jackets for our 4 and 2 year olds.

We experienced a similar fit issue with both out kids between ages 1 and 2. Now that the older one is four the vest fits great. I think the issue is that the chubby two year olds eventually elongate without putting on many pounds. We've floated the kids in the vests and the buoyancy up near the chin is needed to keep their head above water. The four year old and two year old are roughly 30lbs and 27 lbs respectively.

We don't have any issues with the crotch straps but they rarely need adjusting anyway. Could probably just tie them off at the right point.

Josh
 
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