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@HatBeard
Sat down last night with a couple of beers,my gaggia classic, a box of new parts, a phillips screwdriver, my bike allen keys, a small adjustable wrench and some pliers and did the entire overhaul of my system in a couple of hours.
This vid below came in handy for the disassembling bit, I didn't use his numbering scheme though I just took a shit ton of photos on my phone for reference from all angles where something was connected.
https://www.youtube.com/watch?v=N9i-EH7qXOc
where the boiler met the grouphead was really calcified around the outside, I think the boiler gasket must have worn enough that it began leaking slightly, a soak in some descaler sorted it though. the steam wand valve was stuck firm on the top of the boiler too, luckily i wasn't keeping either part.
once you have the machine apart, it's amazingly simple though and bolts together in a very logical way. i understand how it all works much better now and kind of kicking myself for not play around with it sooner.
putting it back together was nice and straightforward, i kept all the screws in a bowl and it's nice and obvious which is for what part so no puzzling over how to re-assemble it.
i finished it late so had to wait until this morning to try it out, instantly had water pouring from a number of places, took the top off and turned it on again, immediately saw the hose connection to the pump wasn't on tight enough, i tightened as much as i could and tried again... no leaks.
as the new pump wasn't fitted yet and the old one was shot I hadn't taken a pump reading before i took it apart on the pressure guage but I took the opv mod guidance from https://coffeeforums.co.uk/showthread.php?3859-Adjusting-the-OPV-(over-Pressure-Valve)-Gaggia-Classic and did a 270deg adjustment on the opv valve and then notched it back a few degrees as my starting position for testing pressure when I got it up and running. after fixing the pump leak I stuck the gauge on and got ~9.95 bar (was aiming for 10) so I think i'll leave it as is and see how i get on.
getting some minor dribbling around the grouphead but when i dismantled it was in need of a clean and the gasket got slightly damaged removing it to put the whole thing in the descaler, got another one on the way tomorrow. will puly caff the shower screen holder today so it's all nice and clean ready for it to go on.
while on amazon looking for the gasket to order I noticed the company i ordered my gauge from had 3 hole nozzles for the silvia wand so in for a penny and all that decided I'd replace the wand and nozzle as well (it was looking quite sorry for itself after all the other new parts).
no coffee today then but once the final bits arrive tomorrow i should be back in business in about 10 minutes.