Alright I got it working, it was infact the new firmware that fixed the problem:
R1BC002_RED36

I used that and XS++ v3.1

Selected Main, FS and Customize all at once, went through tip top no problems again, difference was this time when i turned my phone on i was greeted by the W800 interface :D

Thanks for everyones help, really appreciated.

One more query if anyone could answer, I set my phone to silent but when I'm in camera mode the shutter sound can still be heard? Can anything be done about this? I thought the flash would have taken care of this.

btw i'm from Australia so i flashed with:
W800_R1BC002_MAIN_EU_1_CA_RED36.mbn
W800_R1BC002_FS_EUROPE_2_RED36.fbn

and Customized to Europe_2

I think i've read somewhere that customizing to europe_1 enables a silent shutter?

Also if i did want to recustomize my phone is it possible just to go into XS++ and click "Customize" without doing the MAIN and FS all over again??

Thanks