I used CPF's at first but they were always wet. I would have had to change that kid ever 10 minutes to keep him dry. So I cheated and used disposables (shhhh dont tell anyone!) until he was big enough to fit into his Fuzzi Bunz.
Okay try buying just a handful of more absorbant diapers and then selling off your stash of the other kind. If he's about to potty train and he spends a lot of time naked then you'd probably only need about 5 dipes.
I'm just guessing here but maybe there is a hole in the PUL...try drying once on hot and that might fix it. I know Linda suggests drying on hot a few times to seal the PUL. Good luck. I hope you can figure it out soon.