thanks for the replies guys. I havnt tried a new key mate, as I have two, and they both work faultlessly on the fuel cap filler and seat lock, so am assuming the wear is in the ignition barrel not the key. I was trained as a locksmith when I ran a centre teaching building etc, so I got a reasonable idea of how pin tumbler locks work, and I know the shear line isnt lining up. Im actually useing a locksmithing technique to make it useable lol, so gotta get it sorted.
Have tried all manner of wet and dry lubes including graphite too bud, they worked a year or so ago but are becoming less effective now its got 40k plus up. Think its just a weakness in these barrels, hence I dont want to buy a second hander that may go the same way pretty quickly. Having said that if anyone has a decent one for sale that doesn't look like its been around the clock too many times i'd be interested. :lol :lol