I have cleared the files within the tomtom, installed 9.510 32mb version, then copied over the files and replaced them from 9.510 SE ttsystem. Rebooted and still stuck on the splash screen. I have also tried it without any map installed.

Any ideas please?

What do you mean with "Any ideas"?
How about you start by sticking to one Navcore system instead of mixing them up?
Who sadi anything about installing my 32mb version only to replace the ttsystem with a SE version?
Either you use the original CAB and the SE or just the Navcore from my installer.