Yeeeehaaaaaaww!!
Got it done today with the help of a little lube
Took the alternator down to the garage he helped me out for 30 mins trying to get it off... no go, so he gave me 3 choices:
1) Heat it up, possibly kill the bearings and need a new alternator
2) New Alternator anyway
3) Put a little penetrating oil in the shaft and try again later...
For all he did, and me keeping him back 30 mins or so he didn't even charge me
I opted for 3
Left it for an hour or so and tried again with my father in law. Got the spanner & wrench on, the father in law started tapping the spanner near the base, and after a minute or so it freed up! FML!
I'll post what I found under the pulley later this evening...
Got it al back together about 4 hours after getting it off, including giving it a go ourselves, taking it to the mechanic, filing down the bracket on the alternator as it just wouldn't go back on
NO more noise on full lock, oh my word it's going to be the uber now
Let's hope I've put it all back together properly now, got a trip to Southampton tomorrow
I'll get a PDF made up when I have a few mins free.