Took the whole thing apart again today. Cleaned up the threads some more with a wire brush and re-assembled using PTFE tape as per ChazzyB's suggestion. Guess what... Problem solved
I did a bit of research on fuel and PTFE tape and came to no solid conclusion. For every person who said it breaks down in fuel there was another who said they'd been using it on fuel fittings for years with no problems.
So I went with the voice of experience over science. It may be my undoing
The couplings went in a lot smoother with PTFE too so double whammy of good fortune.
All I need to do now is find a way to lower the exhaust so I can use throw over panniers and I'm good to go.
And also huge thanks to EvilBetty for doing tons of legwork and posting it up so I could find the parts and do the job.

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Wayne