OK, time to own up to one of the most basic noob errors...EVEN THOUGH I KNOW HOW IMPORTANT IT IS ! I missed it.
After cutting more pipes and then convincing my self the internals of the boiler were block I removed it...so I bought an identical model off ebay (for a bargain£45!) which fortunately was only 1hr drive away, except my Volvo decided it didn't want to work now too and having just sold my van for tidy profit (thanks COVID) because I had my 'trusty' Volvo estate
I had to collect it in the Mrs convertible Beetle, what a ball ache.
So after spending a whole day tinkering, replacing unions, fire cementing the flue in properly and generally tidying the whole area to fit it. I didn't have any issue with the oil or bleeding that through which was one of my newly created concerns. But after a whole day actually improving access and the ability to quickly drain the system I had the
new boiler in and working only for it to exhibit the EXACT same symptoms, I can tell you I wasn't in a good mood at this point, this was at 21:00 on a Sunday evening. I was convinced it would solve the problem; it didn't, so I went to bed in a huff.
So the next night, after more head scratching, it
finally dawned on me that the small inverted pipe loop immediately next to the boiler (yes, on the suction side of the pump) MUST have an air lock, fortunately there was a compression elbow on it so I took my stilsons and twisted in blind hope...cue nearly 2 mins of air escaping noise and glugging of water ! I cant tell you how ecstatic I was.
So I left it running for a good 30 mins on the 2 rad circuit I'd created and sat in absolute awe at my achievement. Over the next few nights I recommissioned the rest of the house. I think it was probably worthwhile as the new boiler is in better condition than my old one and is much cleaner. I'll keep the old one for spares. Having now dismantled them both I can't believe how basic they are, so crude.
Thankyou everyone for help and suggestions, I never did find a copy of the manual but not sure I need it now as I now know my boiler inside out!