[brains]

Found it!

At last, I found the problem. I striped another GG and then changed over one part at a time, until the entire front brake assembly was changed over. It didn't feel any better, then Murphy kicked in.

As I was pumping the lever I rotated the bars over too the other side past straight (if the bike was going straight forward) and big bubbles came up. For some reason I was always bleeding the brakes with the bars over to the right, air was being trapped somewhere. All sorted.

Mods it may be a plan to make this sticky as it may save someone a huge headache.