I spoke to tilton uk (on a Saturday) and they thought the same as my mate Al, that the post may have been over extending on the release bearing and in out of true be even 2 thou it wasn't able to smoothly return.

I bled up the clutch again to be sure and then put the car on the ramps with the wheels dangling and ran the car up in gear and then kept adjusting the clutch pedal until it only just operated the clutch, gave it one more turn and now it works perfectly. Tilton said it will improve as well when the clutch wears a bit.

Phew, I was pretty much at the point of ordering the oppliger box and chucking this lot in the corner for another day.