Looks like we may be back in business!
Took apart the print head today and barrel had a little deposit running down the side, no idea why this wasn't picked up when doing the atomic method!
turns out it was a little sliver of metal - the inside of the barrel polished up nicely so it should be fine now!
I still ran into bed leveling issues, installed new firmware and went through the bed level wizard again, works great, but then again after one print needs leveling again!
So I flipped the glass and a couple small prints later it keeping the bed level!
There are still some slight issues where some little bits blob up, but it sticks!
Thanks for all the suggestions, this has been a few frustrating days for me to say the least.