Thanks everyone - eventually got it to work.
View attachment 1885013
From what I can work out, what was happening was that when the first phase of installation was done and the machine rebooted, it didn't see the new installation partition as a valid boot drive so booted off the USB drive again, leading back to the macOS utilities.
So when it was rebooting after the first phase, I pulled the USB drive, forcing it to continue from the ssd. What appeared to be a normal installation then took place (and took maybe 40 mins) and it then rebooted again, at which point I re-inserted the USB drive and booted from that to do a post-install of the patches. When that finished, it rebooted again, taking forever ( 15 mins maybe) but did then complete the setup as normal. Once Catalina was up and running, the Update Patcher utility showed an update was available, which I installed.
At first, the cpu was pegged at 80% with nothing running but after another 15 mins it settled down (Spotlight indexing no doubt) to 82% free. At Idle with nothing running it's around 15% cpu, 2Gb ram and 52 degrees C. The only thing I've found so far to not work is the back lit keyboard. Anyone know of a fix?
Many thanks to
@dosdude1 and the other contributors for their amazing work 👍😁