Tried tweaking hinges; no good so went the Breaking & Entering route. Lock wasn't snapping from the inside (the longest part of a 60/40mm barrel but when I went outside (through the other door) it snapped with very little effort in just a few sideways wiggles! Bit of an eye-opener to see how quick and easy it is to break into one of these doors with just an adjustable spanner and a flat screwdriver! (once you've removed the external lock cover)
Anyway, lock snapped and removed but the unlocking lever that the barrel operates against was still solid. A bit of prodding and wiggling and eventually it clicked across and the door was open. The gearbox mechanism was a bit mucky and there were a few bits that looked a little worn so going to try just replacing the gearbox and Euro Cylinder first to see if it sorts things out.
The rest of the shoot bolt bits seem to be working just fine so hopefully I can re-use those bits.
Thanks for all the ideas and advice. Looks like I'm almost sorted on this niggling issue now.
Cheers Pete