It is not safe to use the harness above the manufactuer's recommendations. You are correct in that what you describe with the way the seat belt fit him is also not safe. Unfortunately there is no add on device that is approved in this situation, that I know of. Unfortunately it sounds as though you are going to need to invest in a new seat. I know that is not the option you wanted to hear, however, it is the safest thing for your son. There are seats on that market that go up to 80 lbs with a 5 pt harness that are the best and safest long term option. The Radian80 and the
Britax Regent both go up to 80lbs. Other
Britax seats,
Marathon, Decathalon and
Blvd have a 5 pt harness up to 65lbs. If cost is an issue there is the Alpha Omega Apex65 which has a 5 pt harness up to 65lbs and then is a belt positioning
booster after that. Maybe someone else will have another suggestion for your current seat, hopefully. However like I said I feel the safest option would be a new seat at this point. Good Luck
Andrea