Hi folks. A quick update. I decided to give the expanding foam a go, so I filled the gaps with it yesterday. I still need to go around with the silicone sealant today.
[Long story alert!!]
Anyway, yesterday I set the mount up in there with the telescope to mark the position where the mount will go. It was forecast to be a clear night so I thought I'll leave the mount setup and have a 'pre' first light. I planned to do some planetary imaging due to the more relaxed polar alignment requirements.

I wanted to get a better Neptune image than my first attempt a few years ago.
So I went out after dark and there I am slewing to an alignment star ...... grind, grind, crunch, clickety click, grind, grind.

What the?!?!?! Cart everything back inside again. That was the end of my 'pre' first light.
It turned out to be the screws for the worm housing on the declination shaft. They had loosened over time and the worm drive had shifted off the gear and was skipping. I decided to strip the Declination axis down while I had the covers off and give it a re-grease and adjustment to try and get rid of a slight binding it had at one position. Two hours later it was back together with fresh grease. The binding seems to have gone but it is still stiffer to turn than the R.A shaft. I can't get it to turn as freely no matter what adjustments I make.
Tonight is forecast to be clear again for the post-pre-first light.

Wish me luck.
Andrew