Update for those interested.
Physio is very concerned. Thorasic spine mainly T6, T7, T8 but also intervertebral joints are causing issues, which I didn't have last time. Also my right side is playing up but nowhere near as painful as left. (Left is injured side from last time)
Rib pain is referred pain mainly from T7 and T8.
Physio remarked she has never worked on someone so stiff before. Next week I need to take Nurofen before going because the facet joints are so stiff; it's very painful (and I'm not a wuss) and she's not working me hard enough to loosen things up very much.
Trying to work out why thorasic is damaged is her priority at the moment. Lumbar spine is very flexible so it's concerning that thorasic is so stiff/painful. My left rotation is basically half of what it should be.
She wants to me to take up my weights again from Monday and wants to see if I'm more/less stiff next week.
She's trying to work out if weights are hindering the problem; I've never been to a physio before weight training and I've been exercising for a long time. I don't want to give up weights but I don't want to go down the surgery path just yet either.