I finally solved this by using a Win XP machine instead of a Win 7.
It took about 3 or 4 attempts on the XP machine to finally get it but I was then able to flash.

Top Tip: Have a recent Backup so that you can restore your apps and settings etc. It makes things much easier after you have flashed the device to restore the settings automatically without having to download everything manually and position all of those icons etc.