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gbj_tester
Thanks for the response, read through your blog post as well! Unfortunately I'm in Derby so trying your solutions likely isn't possible, but thanks for the offer.
It's an 11spd freehub, supplied with the 1.85mm spacer (which i shouldn't need). Got an 11-28 on it at the moment which - remedying the problem mentioned in your blog post I had with the 11-25 - no longer fouls the disc 'skin'. I think this was exasperated by the disc skin having no core, and thus running laterally out of true 1-2mm at points across the wheel.
The chain still runs extremely close to the wheel up on the 28t, might run some paste similar to engineer's blue onto an old chain and see if there's any observable contact. If so I'll try your trick of removing a sprocket.