Hi Julian,
I hadn't mentioned I was in Aus before and so there was no reason to think I was not puttting decent coal into it..
It could just be as simple as poor fuel, but if it was woudl have thought the fuel would have still have been ok to run lightly loaded on the rolling road..
I've taken boiler back out to change the route of the snifting valve. Here's a photo of the firebox. The white stuff makes me think there's a few impurities in the fuel, but I may be wrong.

I'll get some char and try that. I was aware that someone had recently started bringing welsh coal into Aus. I remember it was not cheap and I would have to get it freighted in from Victoria, but I think worth getting a bag to try it.
I'll wait for some different fuel before having another go.
Greg