So, key has been filed, taken back to cutter to tidy up/file down some more..
now works well in drivers door and ignition, but not at all in boot or passengers door.
Thinking (suggested by key cutter) that locks are worn as well as key, making it near impossible to cut a new key to work properly....
Will now be contacting auto locksmith to see about getting a key cut from the barrel or seeing if they can be fixed to suit a new key..
On the upside, got instructions on how to get my 2nd alarm fob re-synced to the alarm so both will work =)
Maybe if you smile and wink nicely at them they will take a liking to you..