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It was the mudguard! Annoying as I'd spotted it ages ago and asked numerous respected mechanics about it and their answer was all firm 'no this is not your problem'.
Repaired mudguard with araldite and some wire to enforce it. Mudguard is also the fork brace as its a short travel single crown scooter fork.
Fork and shock now feel basically bottomless, pretty good for 85mm travel. I knew it could be achieved despite most folk constantly saying 'just buy a CB500x' (the only big bike thats easy to buy new/used and is legit on paperwork), which of course has orifice tube dampers too.
Emulators are great. Change the oil weight for rebound, fiddle the compression adjuster for low speed compression adjustment, high speed is blown off by the weight of the spring/size of the holes in the metal piece. Wont' fiddle with it anymore, does now exactly what I want it to do which is make an under powered midi scooter tolerable for 8-14 hour days.
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BrickMan
Did this get sorted? My bet is on the cartridge emulators- I had an F650 that had them and it had a horrible rattle as the forks would chatter as the forks topped out on uneven surfaces. I think some of the conversions do this.