This wens away and then started coming back again, and I think I have found what is causing my error, apart from me:)
In my original post I stopped the g-code at the G0 X208.659 Y25.039 line but it is the line after the is causing the problem. That is a G43 and the H value points to a valid tool but not the one I am using. It is loading the offset for whatever that tool last touched off to.
Even if it was right tool it would be whatever the last tool touch off measurement that was stored in the tool table.
Unsure why running the job again fixes it, but pretty sure that is the problem.
Sorry for screwing you around, but thatnks for the halp.
