Just had another tinker now and things are kind of improving. Coil and battery both check out OK. I don't think I said it originally, but the lights were working opposite to each other too, but after having grille and lights off I found a broken earth behind the lights and now they both work as a pair. 1 problem sorted. The main problem however remains. To simplify it, it's as if the more the power to the lights, dip, main, full, the less power gets to the instrument cluster, till nothing.
Dip, cluster works
Main, cluster lights dim, rev counter drops
Full, cluster dies
I'm trying to get around it in my head as to how the lights would affect the cluster. Do they run off the same relay in the fuse box? Would the 2 relays behind the passenger headlight affect the amount of power going to to the lights. Is there an auto electrician on this forum? Again, any suggestions welcome!