Thank you HF, Stefano & finally Janet for your help. Without it the pain would have been much worse.
After following your advice, I managed to do a clean install, restored the last know backup, then sort the remaining problems.
The last one was particularly time consuming. This is what was happening. Client was using outlook, all new email was coming in fine, however none of the existing restored email would show. Read numerous googles on how crap Outlook was with IMAP, chased numerous wild geese. Installed Thunderbird and all the email showed up? Did a clean account with Outlook, and the problem was still there.
Not sure who it was said check the logs, but I should have listened. There it was staring me in the face, access denied to blah,blah,blah in imap log.
Set chown to each user on their Maildir and away it all went!
Thank you all so much again, was really suffering from wood and trees!
Paul.