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@myfavouritegreek
Some progress. The noise is down to a gentle rattle now. Things that helped were:
Positioning teeth in the middle of the chain rollers by experimenting with a different width spacer along rear wheel axle. What I originally thought was a perfect chainline was still about 2mm out. This was increasing noise as it moved against the inside plates of the chain.
Backing off the tension of the chain at the tightest point and giving it some slack.
Using a 3/32 sprocket.
Large dose of Finish Line on the inside of the chain rollers.
I also learned about chordal action along the way which turns chain friction at certain speeds into vibration. A higher tooth count on the sprocket (16 to 18) has helped a lot with this. So I don't think it was a single problem, more combination of lots of factors.