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@chill123
the apparent fix was:
1) the thread on the bolt was a bit chewed up (maybe caused by me trying to tap it down when the expander bolt was stuck in in the first place). with it removed i slowly worked the thread through the expander nut while holding that in place with some mole grips.
2) lubed the thread on the bolt and threaded up/down the nut to help reduce friction
3) cleaned the outside of the expander nut to ensure there was no grease on it to maximise chances of it biting the inside of the stem
4) tapped the expander a little inside the stem before assembling to ensure it got some purchase to start with.
seems to have worked once. will need to try to remove/reassemble a couple of times to avoid a foreign ride fail!