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@AngelD
Had looked at the chain, but gave it a better check of each links vertical and horizontal movement and its fine, full oiled and free moving with no kinks.
The hub freewheel is a standard geared version, with spacers and sprocket. Sprocket is pretty tight in there and looks as straight as it can be.
Had the spring wound damn tight on the tensioner pulling up before and it was still slipping.
Chainring is brand new, and has less than 1mm horizontal movement, which I'm pretty sure the chain would take up the slack of. Want to replace with a 40-42t SS ring anyway, so will see if that helps.
Apart from that, am pretty much at a lose as to what it could be!