Jamie Crooks wrote:Thanks everyone for the input.

Quick solution, i stripped out the Hub with the wheel still attached, took it to the local bike shop and with a bit of magic and £5 later the two parts were separated :D

Out to the garage tonight to grind of the offending powder coating and fit new disc before putting it all back together again.

moral of the story - i was being bone idle lazy by not buffing off the powder coating in the areas i should have