Some questions: Did you guys swim out to the dive location? Long walk to the water? Kayaking? I wear 5mm and can overheat if I don't keep my movement to a minimum before getting in the water or have too much of a swim.
And some suggestions:
- Have your buddy really hang loose in the water as extra movement like fidgeting and 'trying to flood the suit' can generate the excess heat.
- Put a small flexible tube (Tygon tubing) down his face suit opening down his neck area so cold water can circulate through and cool him off.
- You can have your buddy soak the suit in the cold water before putting it on, that might help too (for a short while.)
- Dive without expending much energy (say free immerse down a line) so the compressed wetsuit can let some coldness through from the water. Find a friendly thermocline.
Peter S.