Well, the old machine is printing again. A bit hard to believe considering how far down we pulled it apart. About 100 M3 screws in all. We have about six left over even though all panels are now on - including two red ones which the manual said must never be touched!
After many years in tecnical employment, much of it in laboratories with complex electromechanical equipment to keep operating, the process wasn't too daunting. We have the three main manuals to go with a 6100 which are highly detailed but lack some key info. Our error code pretty much said the problem was the main data cable from the motherboard to the head. No info on changing it, in fact with our model you'd have to change the carriage and cable assembly, not just the cable.
It looks like our wiggling the ends around has done a re-seat, and we are printing again.