Thought i better update this thread. The problem was with the clutch bracket that attatches to the bulk head, 3 of the 4 spot welds had broken away, so the bracket was flexing hence getting less clutch travel.
We managed to access the spot welds by removing the wipers and the plastic panel that sits below the windscreen. So we didnt have to remove the dash. Got a pretty decent weld from there, but may still strengthen it from the insde if i ever have the dash out for any reason.
Dont know how this ties in with the gear selction getting worse when hot, maybe after driving for a long time or sitting in traffic the bracket was flexing even more, getting even less clutch travel.
Anyway cheers for everyones input
Oh and if anyone trys this remember and have someone on fire watch inside the car lying in the footwell, with the garden hose on standby :lol: