Ok so short version is I had to drop the knuckle and hub assembly out of the lower front control arm (to replace a cv boot) and the strut was hanging by the top mounts.  After manoeuvring back into place and everything back in place and torqued up, including the axle bolts. The top of the strut, suspect mountings or bearings creaks like a wooden rocking chair. I didn't touch the mounting or bolts but like I said, it was hanging and moved about.

 

Could the upper spring locator or top mount have moved?  From memory they're pretty specific and well located...  

To update and close out my own thread. Of course it was the top mount and bearing. Mostly the bearing by the looks of it.

 

I must have fatigued it manoeuvring the strut when just hanging from the top mounts.  The inner parts of the bearing were slightly cracked, it actually looked like the bearing wasn't totally aligned with the cut out in the top mount as well. Although the bearing still turned ok without load.  More care to be taken if I have strut hanging again. Mind you the top mounts are 60k and nearly 6 years old.