Yes i agree it could be slightly out on cam/crank but not enough to cause a fuss about.

Fitted new starter and it seems to have helped, it starts and runs not what i would call "sweet as a nut" but ok with a good amount of power.

Customer seems happy with it now as he also supplied the engine so all is good, bill is payed!!
Thanks for all your help and i definatly wont be changing another engine if i find similar things different.