Thanks Alge, I think I was clicking the accepts too quickly and with the lag the group was being formed differently each time.

Doing it slowly put all the members in the correct order so now the party frames line up with my VideoFX click throughs.
Also put in the healers cast bar to make sure they were doing what they are meant to, sometimes key presses get lost.

Team is at 12 and having fun
This is a great world. Kojan seems huge and is the smallest of the 3 areas. I think I am going to buy a boat with one character and do some exploring, I assume I can just load the other characters up on to the boat and go?
It is great there are no (visible) zones. You can just run and explore