Ok maybe i did a little too much too soon, I read through the code and took a reasonable understanding and then integrated it into my asm files, making changes (which should not have affected fuctionality).
Now Ive gone right back to basics, on tutorial 12.1 making only the changes necessary to operate on the PIC18F2520 (ie header, include, my config, changed I/Os, FSR,INDF -> FSR1,INDF1, removed bank selection RP0/RP1, changes rlf ->rlcf, clrw -> clrf w) No other changes.
TX: No problems, 20 header 1's generated followed by 0.
RX: Almost always the header detected is too short, (usually bitcnt=7), and sometimes I get no mid frame transition errors.
From a comms point of view my setup is pretty ideal, lamda/4 antenna in close proximity, 19 of the 20 start bits appear clearly at the PIC input. I have even removed the RF and placed a wire between the two micros, the errors are the same