thanks DB, makes a big difference being able to open up and not end up in a corner!
New motor fitted now, but I doubt it will be over with this, I never feel settled! Its a Turnigy 800kv outrunner. Over the last 2 yrs brushless knowledge has come on leaps and bounds, and people are getting good results with lower kv motors, and as the align motor was getting a bit rattly, I thought it was time to try a lower kv, bought second hand off fleabay, so if successful I will get a better quality one.
The theory being, lower kv, more torque, able to swing a bigger prop. After some significant testing over the last 3 weeks, and changing gearbox ratio, I have arrived at 16 teeth on the driveshaft, and 14teeth on the motor shaft, 1.14:1.
1:1 was ballistic, 25.55mph on a 55mm "x" prop, but everything was way too high, amps almost 100 max, hot motor, but geat fun

1.25:1 delivered 21mph, so no real improvement on what I had, but this seems (for the time being anyway!) ok, although motor was hot after stopping, cool when running, must be something to do wiith all the heat build up when the outrunner stops turning, so I need to come up with some sort of "after running" cooling system device.
video shows first run with a 50mm "x" prop that delivered 21.5mph, then second run with a 55mm "x" prop 23.85mph, 1589 watts and 80 amps, so its within tolerance of this motor, and very fast!
http://youtu.be/e5-YmmElIfk