I've been tinkering with pump and boiler settings ever since my first post but the problem has never gone away, and seems to be getting worse. The noise now isn't really focussed on the pump, but in the pipes near the pump.
What happens now is that if I switch on the Hot Water only, I get gurgling pipes, banging and the boiler overheat switch trips after a few minutes (and the boiler front feels very hot to the touch).
However, if I switch on the Central Heating first, for maybe 10 minutes, and THEN start the Hot Water, there is less noise. It's as if having the CH on is giving the system a boost or something, and helping the HW system.
I'm guessing the flow of water is the culprit here somehow but does it sound more like a malfunctioning pump or a cold water inlet blockage?
British Gas Man is coming next week to check it out, and it would be good to be armed with a few suggestions!
TIA