Thanks for all the help so far guys - I am trying to let this one last run through complete, then I'll check for a massive *1 file. Failing that I will go for the full rebuild with Mark's latest BigDisk - which I would have had to go for at some point anyway I'm sure.

And I have retrieved a machine with proper serial ports so I can give it a shot this weekend.

(I want to make sure it all works before Cambridge!!! :-)