Thanks for the comments guys and all your advice Mark..
1. I'm not sure if my collimation is spot on, i'll take a video of an inside and outside focus sirius tonight once it rises, but it won't be too high.. maybe i'll try canopus as it'll be a bit higher.
2. I don't have the luxury of only using the middle of the FOV, because I don't have tracking. With a 2x barlow, the object drifts out of the FOV in around 10 seconds, so I basically have to start recording once it's fully in the FOV and stop recording before it hits the other edge. If I only used the middle, i'd be lucky to get 5 seconds worth of frames and it'd take my 20 joined videos to get enough frames to reduce the noise

Re-aligning with the 2x barlow is frustrating enough 3 times let alone 20

I know what you're saying though and I do agree with you, i'll see what I can do.
3. The conditions were pretty bad, seeing was terrible in the videos as the image swum about.. plus dew was really bad, it was literally dripping off the trees above my head. I had to pack up sooner than usual because my mirror was collecting dew and my finder was all fogged up.
4. Yes, some frames are clearer/crisper than others as it drifts across the FOV, mainly due to the seeing i'm guessing but I suppose part of it could be due to coma as well.
I think I also need to be more selective in registax when choosing the frame to base the alignment/optimisation off.. sometimes I just choose the first frame, instead of finding one where the image is clear and sharp.
It's difficult to tell how good it looks sometimes though, because with the gain and gamma so low, it's hard to see the darn image at all, let alone see if it's clear and sharp with the cassini showing etc.
Anyway i've got some more stuff to work on, part of it was definitely seeing and dew this morning, but collimation and coma most definitely could be playing a part too.
I also just need to capture enough frames to be able to stack > 500 and reduce the noise.
It's all practise anyway, only my third time out with the ToUcam so i'm sure i'll improve eventually..
Thanks again.