Thanks for the info guys.
Sounds like I need to get it to someone to have it checked out. (I'm thinking of getting in touch with Stu at M Developments for a live mapping session)
For info, car is running standard fuel pump (its a saph 4x4 btw) and the plug that melted was an AGPS 092P.
I've now put in a set of AGPS 071C and it's much much better. Still a slight miss at about 5500 in 4th.
rosco22, sorry to here about your misfortune mate. I've been there before. Not nice.