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I don't want to go at it with a hammer just yet, as the cone on the DS is still attached and I don't want to damage the bearings.
Outer nut is seized, got it. For applying heat on that nut, a hair dryer or pouring boiling water over it would stand the best chance. The radiator is going to be relatively slow heat, so the axle inside the nut is given more time to absorb heat and expand as well.
You’ll probably still need more leverage though. Either a vice, a longer tool, a pipe or other extender for the tool you have, a counterforce like a foot or a friend pressing down on the opposing tool... That’s the order of what I would’ve done in the shop if it was needed in a rush. If no rush, fill a cup with 1” of chemical tools like rust remover and put the nut in overnight.
Just to clarify the hammer suggestion: My suggestion is to tap a large flat screwdriver or a pencil-sized punch along the dust cap where I’ve put orange dots and all around. Hopefully the cap isn’t too rusted on, and it should shift in towards the hub enough to expose the cone flats.
If you look at the part I’ve surrounded with a green rectangle, it looks like there’s a 1mm space between the steel ring and the yellow/green spacer on the axle. I think that space is there because the steel ring is a metal dust cap (like @Alexnharvey also thinks and helpfully rephrased), and it’s made its way out and is now covering the spanner flats on the cone. The dust cap isn’t attached to the cone except by a tight fit, and possibly rust in this case.
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Adhiero
Basically, its that outer most bolt that is stuck. Just wont budge. Tried as you suggested with wd40, and as @Alexnharvey suggested with the nut on the other side but still no luck. I've leant it up against the radiator for now, and i'll come back to it later with a hairdryer to see if the heat helps loosen it off.
I don't want to go at it with a hammer just yet, as the cone on the DS is still attached and I don't want to damage the bearings. If I can however get a tool inside the freehub body to grip the cone nut on the DS, then I might be able to get some purchase on that pesky NDS lock nut. I tried with my pliers gripping the DS cone bolt but it keeps slipping.
Also checked already to see if I can slide a 5mm or 4mm inside the axle and there's no hex hole unfortunately :-(. If I can't sort this afternoon I give the LBS or local engineer a ring I think!
Thanks a lot for all of your help and suggestions! I let you know if I manage it :-)