Kerbal Ragdolls Instantly on EVA

[Musicrafter]

I have a save game I'm playing now, and I have a ship currently on a Mun flyby. I plan to take a lander down to Mun, then perform a hyperbolic rendezvous with the main ship on a second Mun flyby about 18 days later.

The trouble is, when I try to EVA Bill Kerman and get him to the lander seat, at about 600km above the Mun's surface, he IMMEDIATELY ragdolls and gets flung out at about 5 m/s relative to the ship. He breaks several of the still-retracted! SP-L 1x6 solar panels mounted to the lander can I just took him out of. Should breaking retracted solar panels even be a thing? I can usually recover using a quick time warp burst, then fly him back and get him in the lander seat, but I don't want him breaking my ship!

I have not been able to get him to successfully and safely EVA at all. Is something wrong with my save file or something?

Edited June 4, 2016 by Musicrafter
clarification

[FullMetalMachinist]

6 hours ago, Musicrafter said:

The trouble is, when I try to EVA Bill Kerman and get him to the lander seat, at about 600km above the Mun's surface, he IMMEDIATELY ragdolls and gets flung out at about 5 m/s relative to the ship.

Can you post a picture of your ship? There is a known issue that if there is something too close to the pod hatch there will be some collision forces when you EVA a kerbal. Basically, when the kerbal spawns on the outside of the pod, if there's something too close then they "hit" it and get thrown away. 

[Claw]

Yes please. A picture or a save file of the offending craft (or the .craft itself) would be helpful to diagnose the issue.

Cheers,
~Claw

[Malich]

As above,  pic will help but at a guess you have something near the door the kerbal is clipping when he evas