These bloody insulators!
Found out the "better" one of the two I had was actually split on the right hand boot.
Probably been like this all along, just adding to the problems.
Got the other boot on, waiting for the threebond to set before I can leaktest again.
If I've learnt anything from this rebuild it is LEAK TEST!!!!
Best $20 you can spend on your bike is a dodgy, home made leak tester. Will save a lot of time and $$$$ if you do.