Just thought I’d update this thread in case someone 10 yrs down the line has the same issue.
I haven’t yet confirmed if I’m correct but it all points to simple stupidity on my part, I’d read on different forums that the load spreader plates that sit on the CV joint and spread the load over the thin CV tin boot were pointless...and pointless as they may be, the bolts included with the new stub shafts assumed you were fitting the damn load spreader plates so they are too long without the plates. Once you start loading up the hub nut they bloody grip on to the inside hub.
Result is I’ve got the inside of the hub being chaffed away by the 2-3mm oversized bolts. I must add that the hubs are aluminium and bolts 12.9HT, needless to say who won that battle. I don’t think it’s an issue with the hubs having a little groove rubbed off on the inside as there’s no matting surface affected, but it certainly is a learning point.
These spreader loads are quite hard to find but I’ve managed to get some on eBay. Will update again once these arrive to see if they’ve sorted the problem - shame it will be a long wait now with Christmas holidays.