Well this all turned out to be quite simple really, the bearing outer cones were easy to press into the headstock casting..

The inner race was pretty easy too.... the second time around as I forgot the bearing cover the first time


once the gear, spacers and the other bearing was fitted, the spacer on the outside was obviously (as you guys predicted) about 4mm too long.

But after some careful fettling without the preload, the key fitted perfectly.

All reassembled and run for a few minutes on at a lowish speed and the re-adjusted I'm amazed at the results, a much smoother cut with no chatter on facing cuts which is where I now realise I was having problems before.
It amazing, I've ended up with a much better machine thanks to you guys. I only wish I could have got hold of those metal gears but hey, you cant have everything can you

Thanks to all those who offered help and advice
You guys are the dogs danglies.
David